Tivoli Maximo Asset Management – Functional workshop Exercise - 007 Job Plans, Safety Plans, Preventive Maintenance, Routes, Meters, and Conditional Monitoring Page 1 of 32 Tivoli Maximo Asset Management – Functional workshop Exercise - 007 Job Plans Introduction A job plan is a detailed description of the work tasks (operations), labor, materials, and tools to be performed for a particular type of job. Use job plans as templates for work order-specific work plans. You use the Job Plans application to create, modify, or delete job plan records. A job plan is a detailed description of work to be performed for a work order. You can copy job plans to PM records, routes, and directly to work orders. After a job plan becomes a work plan on a work order, you can modify the work plan without affecting the job plan. Job plans generally contain tasks (procedures), along with lists of estimated labor, labor hours, materials, services, and tools required for the work. To ensure that work on an asset is performed in a safe manner, you can add work assets and associate safety plans that can be used when work is performed. Accessing Job Plans This table shows you how to access the Job Plans application. Step 1 Action From the Start Center, click Go To > Planning > Job Plans. Result: The Job Plans application launches Page 2 of 32 Tivoli Maximo Asset Management – Functional workshop Exercise - 007 Job Plans, Continued Tabs The Job Plans application is comprised of three tabs: Tab List Job Plan Work Assets Specification Sub-tabs Description Use any combination of fields to query and find records matching the data in those fields. Create, modify, or delete a job plan record. This tab displays basic information about the job plan, and specifies job plan tasks and resources. Use to associate assets, locations, or items to the job plan, as well corresponding safety plans. This tab also allows you to specify whether to create a work order when an item is purchased. To classify (or reclassify) a job plan and specify attributes to define it further. For example, a job plan might involve the classification of a pump, with attributes of rpm, diameter, and speed, for which you can define values. Attributes help to categorize job plans, which makes it easier to find and manage job plans. Note: You also can classify a job plan on the Job Plan tab, but to manage attributes for the job plan, use the Specifications tab. The Specifications tab also lets you specify attributes for job plan tasks that you classify on the Job Plans tab. The Job Plan tab has four sub tabs: Labor, Materials, Services, Tools. Each time you insert, delete or modify quantities or hours in the sub tab table window, the cost fields update automatically. Tab Labor Materials Services Tools Description Maintains a list of labor and crafts for the job plan. Maintains a materials list for the job plan. When you enter a service item that has a default vendor, Maximo enters the default vendor and the unit cost for the service. Maintains a tool list for the job plan. Page 3 of 32 Tivoli Maximo Asset Management – Functional workshop Exercise - 007 EXERCISE – 7.1 Creating a Job Plan Follow these steps to create a Job Plan. Step 1 Action Click the Insert New Job Plan button on the tool bar. Result: a new record is created and displayed. 2 Complete the Job Plan Code and Description fields with the following information: Field Job Plan Description 3 Value JP-XX-MON (where XX are your initials) Monthly Inspection Click the New Row button in the Job Plan tasks. Result: A new tasks row detail is displayed with the Task number defaulting to 10. 4 Enter a task to complete. ‘First steps to perform month overhaul’ 5 Click the New Row button. Page 4 of 32 Tivoli Maximo Asset Management – Functional workshop 6 Exercise - 007 Enter a second task to complete. Result: Your screen should look similar to this: Planning Labor 7 Click Save. 8 Note that the task id’s getting generated in multiple of 10. It’s a good practice to have taskid’s generated in this fashion which allows addition of new steps in future if required in between of existing 2 steps. When planning for Labor in a Job Plan you can plan for actual people or Crafts. Typically, you would plan for crafts since they tend to remain static over time whereas people change. Step 9 Action On the Labor sub-tab, click the New Row button. Result: a new row opens in the labor sub tab. 10 Look up or enter a valid Craft. e.g – Select ‘ELECT’ as one of the valid craft. 11 Enter the 2.25 hours in the Hours field. Page 5 of 32 Tivoli Maximo Asset Management – Functional workshop 12 Exercise - 007 Optional: Repeat steps 2 and 3 for additional craft/labor assignments. . Add MECHANIC 1st Class as a 2nd craft and add hours as 1.5 hours. System will convert 1.5 hours to 1:30 [as 1 hour, 30 minutes] 13 Click Save. Page 6 of 32 Tivoli Maximo Asset Management – Functional workshop Planning for Materials Exercise - 007 There are two buttons to plan materials for a Job Plan They are: • Select Spare Parts • New Row Step 14 Action Click the New Row button. Result: the material detail line expands. 15 Add the following item: FIL-100 and VAL-500 Click NEW ROW and select item = FIL-100 Enter a valid Storeroom. [Central Store Room] 16 Add 2nd Item Click NEW ROW and select item = VAL-500 Enter a valid Storeroom. [Central Store Room] Page 7 of 32 Tivoli Maximo Asset Management – Functional workshop 17 Exercise - 007 Save the Job Plan. Result: Your screen should look similar to this: 18 You can make use of task id to link the material/labor requirement against the task as mentioned above. Page 8 of 32 Tivoli Maximo Asset Management – Functional workshop Exercise - 007 Services and Tools The steps to plan for Services and Tools are similar to the steps covered already for labor and materials. For time purposes we will not cover them now. Work Assets The Work Assets tab lists locations, assets, and items associated with the selected job plan. This table teaches you how to associate a Work Asset with a Job Plan. Step 19 Action On the Work Assets tab, click New Row. The Row Details open. 20 In the Location, Asset, or Item field, enter a value or click Detail Menu to select an option and retrieve a value. 21 You can choose the location report [0560-XX] that you had created in previous exercise. 22 Click ‘Save’ to save the Job Plan Page 9 of 32 Tivoli Maximo Asset Management – Functional workshop Activating Job Plan Exercise - 007 A Job Plan’s status must be Active prior to being used in Work Order. When a job plan is created its default status is Draft and is considered Inactive. Here you learn how to activate the Job Plan. Step 23 Action Click Change Status tool bar button. 24 Click the New Status drop-down arrow. 25 Select Active. 26 Click OK. 27 Click Save. Result: the Job Plan is now active and can be used in work orders. Page 10 of 32 Tivoli Maximo Asset Management – Functional workshop Using a Job Plan Exercise - 007 Once created, Job Plans can be called by a work order on an as needed basis. When you call a Job Plan on the work order, the work order’s plan is populated. By this method, Job Plans can be used over and over, whereas a work plan is created one time for a single use. We will create work order in later exercises. At that time we will make use of this job plan. EXERCISE – 7.2 Duplicating Job Plans You can save time and effort when creating a number of job plans, especially when creating job plans for preventive maintenance. Make use of this feature to create 2 additional job plans. One for quarterly maintenance and one for yearly maintenance. Include some additional tasks in quarterly and yearly maintenance job plans along with required labor, tools, material and services. Step 1 2 3 4 Action Go to Job Plans Query for your Monthly Job Plan created earlier Click Select Action > Duplicate Job Plan. Result: A new job plan is created Complete the Job Plan Code and Description fields with the following information: Field Job Plan Description Value JP-XX-QTR (where XX are your initials) Quarterly Inspection Page 11 of 32 Tivoli Maximo Asset Management – Functional workshop Exercise - 007 5 Add two additional tasks. Be sure to label them as quarterly tasks. 6 Modify the labor and materials to accommodate the additional tasks. 7 Activate the Job Plan. 8 Repeat Steps 3-7 making an Annual Job Plan. Result: When you complete this exercise you should have three job plans: • JP-xx-MON • JP-xx-QTR • JP-xx-ANN We will use these 3 job plans with a PM [preventive maintenance schedule] which would use first monthly job plan for 1st and 2nd month, Quarterly job plan in 3rd month, again monthly job plan for 4th and 5th month, Quarterly job plan for 6th month and so on. Lastly, for 12th month, the annual job plan will be applied as per the job schedule. Page 12 of 32 Tivoli Maximo Asset Management – Functional workshop Exercise - 007 Safety Plans Introduction Safety Plans allow you to associate safety requirements and procedures with work orders to fulfill regulatory requirements of agencies or government entities. Safety Plans inform employees of hazards they might encounter while performing work, as well as precautions they must take to prevent accidents. The Safety Plans application is used to define those safety procedures. Safety Plans can be either generic safety plans for use on all work assets or location, or for use when working on a particular work asset or location. Safety Plans can also be used independently of locations or assets. Accessing Safety Plans To get to the Safety Plans, follow the steps below Step 1a Tabs Action From the Start Center, click Go To > Planning> Safety > Safety Plans. There are five tabs in the Safety Plans application. They are explained here: Tab List Description Allows you to search Maximo for safety plans. Page 13 of 32 Tivoli Maximo Asset Management – Functional workshop Safety Plan Hazards and Precautions Hazardous Materials Tag Outs Exercise - 007 Create safety plans, add and view work assets associated with a selected safety plan. Add and view hazards associated with the selected safety plan and view the precautions for those hazards that you defined in the Safety Precautions application. Add and view hazardous materials associated with the selected safety plan. Add and view hazards for work assets and tag out procedures associated with each hazard. EXERCISE – 7.3 Creating a Safety Plan Here you will create a safety plan and associate it with a location. Step 1 2 Action Click the Insert New Safety Plan icon. Result: a new Safety Plan screen is displayed Type the following: Field Safety Plan: Description: Value SP-xx-01 xx-On Site Safety Gear Note: replace ‘xx’ with your initials. 3 Click the New Row button. 4 Enter or lookup a valid location. E.g. ‘0560-XX’ Result: Your screen should look similar to the screen here. 5 Click Save. Page 14 of 32 Tivoli Maximo Asset Management – Functional workshop Hazards and Precautions Exercise - 007 Next we add the hazards a worker can encounter and the precautions the worker must take to mitigate the hazard. Step 6 7 8 9 Action Click the Hazards and Precautions tab. Click the New Row button. Enter the following in the Hazard field: Noise, Heat, Dust, and High Voltage Result: the description for the hazard populates the field along with the Precautions to take for the hazard selected. Click Save. Your screen should look similar to this: Page 15 of 32 Tivoli Maximo Asset Management – Functional workshop Going on from here Exercise - 007 Your safety plan can now be associated with other Job Plans, Locations or Assets. Furthermore, this safety plan can be called when creating a work order. Let’s now attach this safety plan to the all three job plans that have been created in previous exercise. JP-xx-Mon, JP-xx.Qtr, JP-xx-ANN Page 16 of 32 Tivoli Maximo Asset Management – Functional workshop Exercise - 007 Preventive Maintenance Introduction Earlier in the Job Plans chapter you created three job plans. They were plans for a monthly, quarterly, and an annual inspection. We will use those plans during this chapter EXERCISE – 7.4 Creating a PM Here you will create a Preventive Maintenance record. Step 1 Action From the Start Center click Go To > Preventive Maintenance > Preventive Maintenance. 2 Click Insert New PM. 3 Complete the following fields: Field Description Asset Value Equipment PM Inspections AHU-100 [This is the same asset that you had created in previous exercise] Note: Write your PM number here: _____________________ Page 17 of 32 Tivoli Maximo Asset Management – Functional workshop Exercise - 007 4 Type JP-xx-MON in the Job Plan field. Where XX are your initials. 5 Note: You created and Activated three job plans in the last chapter. Click Save. Result: Your screen should look similar to this: Adding Frequency Next you will add the PM’s frequency. Step 6 Click the Frequency tab. Action 7 Complete the following: Field Value Frequency 1 Frequency Units MONTHS Page 18 of 32 Tivoli Maximo Asset Management – Functional workshop 8 Exercise - 007 Click Save. Result: Your screen should look similar to this. Define ‘Estimated Next Due Date’ as today’s date. Sequenced PMs As your PM stands now, you have created a single PM that will generate WO every month. Next we will sequence the PMs to include quarterly and annual inspections. Step 9 Action Click on the Job Plan Sequence tab. Result: Your screen should look like this: 10 Click on the New Row Button. 11 Type the quarterly job plan created in the last chapter: JP-xx-QTR. 12 Type 3 in the Sequence field. Note: when saved this means every third time this PM is generated the Quarterly Job Plan will be used. Page 19 of 32 Tivoli Maximo Asset Management – Functional workshop View Job Plan Sequences Exercise - 007 13 Click on the New Row Button. 14 Type the Annual job plan created in the last chapter: JP-xx-ANN. 15 Type 12 in the Sequence field. 16 Note: when saved this means every 12th time this PM is generated the Annual Job Plan will be used. Click Save. The PM now calls for 3 different job plans, monthly, quarterly and annual. Next, look at the sequence: Step 17 Action Click Select Action > View Sequence. Page 20 of 32 Tivoli Maximo Asset Management – Functional workshop Exercise - 007 18 The Job Plan Sequence is displayed. 19 20 Change status of this PM to ‘Active’ You can now ‘test’ the sequence by generating work orders. Page 21 of 32 Tivoli Maximo Asset Management – Functional workshop 21 Exercise - 007 Generate work orders using ‘Select Action’ for next 95+ days, and check the job plans on the work orders. In this scenario, system would create 4 work orders with first 2 monthly job plans, 3rd WO with quarterly job plan, and 4th again with monthly job plan. ? DO YOU KNOW WHY SYSTEM GENERATED 4 WO ? Now, go to workorder application, and review all these workorders. Page 22 of 32 Tivoli Maximo Asset Management – Functional workshop Exercise - 007 Routes Introduction A route is a list of related work assets, which can be considered ‘stops’ along the route. These route stops can be assets or locations, or a combination of the two. A route can be a simple asset list. You can also create a route that lists assets that are related by location, for example all of the servers in a computer lab, or by type of asset, such as all fire extinguishers located throughout the site. Routes simplify building hierarchies of work orders for inspections. You can use a route in the following ways: Apply the route to a preventive maintenance record to generate inspectiontype work orders for all work assets listed as stops on the route. Apply the route to a work order and generate child work orders for each work asset listed as a stop on the route. EXERCISE – 7.5 Creating a Route Here you will create a Route record. Step 1 Action From the Start Center click Go To > Planning > Routes. Page 23 of 32 Tivoli Maximo Asset Management – Functional workshop 2 Click on the New Route Button. 3 Enter Route as ‘RU_NEW’ Exercise - 007 Click on ‘Select Locations’ and select all four ‘0560-XX locations’ as created before. Keep selected the first radio button option selected ‘Child work orders’ 4 5 Click OK and Save the record Now, let’s apply this route to a PM and trigger-off the work orders. From the Start Center click Go To > Preventive Maintenance > Preventive Maintenance. Page 24 of 32 Tivoli Maximo Asset Management – Functional workshop 6 Exercise - 007 Click Insert New PM. 7 Enter details as below – Description – PM using Routes RU_NEW Route – RU_NEW 8 Click ‘Save’ Change Status of this PM to ‘Active’ Click ‘Select Action’ And Select ‘Generate Work Orders’ Page 25 of 32 Tivoli Maximo Asset Management – Functional workshop 9 10 Exercise - 007 Uncheck ‘Use Frequency Criteria’ Click ‘OK’ System will generate the total 4 workorders corresponding to each location record which we had added in this ‘ Route’ Verify details of work orders. Page 26 of 32 Tivoli Maximo Asset Management – Functional workshop Exercise - 007 Meters A meter record in Maximo is a virtual identifier used to record measurements. You associate meter records with assets and locations to record measurements, for example run hours, temperature, or pressure, that are used to track asset and location performance. You use the Meters Introductions Meters application allows to define a meter record along with the type of meter, the unit of measure used by the meter, and the type of reading (delta or actual) that the meter should record. Meter records can be associated with assets, inventory items, and locations, and can be used to drive condition monitoring and preventive maintenance. Meters can be applied individually, or as part of a meter group. Continuous . Meters where the readings increase continuously, for example odometers. These meters might be used to track miles, hours, engine starts, pieces produced, fuel consumed, and other continuous readings. Gauge . Meters where the readings may fluctuate, for example thermometers or pressure gauges. These meters might be used to track temperature, pressure, noise levels, oil levels, and other readings that fluctuate. Characteristic . Meters where an observed state is being tracked, for example a color change. These meters might be used to track Brick/Refractory Color (Yellow, orange, white), or oil color (Clear, Turbid, Dark). Step 1 2 Action From the Start Center click Go To > Assets > Meters Click ‘New Meter’ Page 27 of 32 Tivoli Maximo Asset Management – Functional workshop 3 Exercise - 007 Enter details as below – METER – TEMP-PUMP Description – Temperature meter for Pump Meter Type – Gauge Unit of Measure – DEG-C 4 Save the record. Page 28 of 32 Tivoli Maximo Asset Management – Functional workshop Exercise - 007 Conditional Monitoring Introduction Maximo uses measurement points as one possible criteria for generating PM work orders. If a measurement is entered that reaches an upper or lower action limit, a PM work order can be generated for the asset, either automatically via a cron task, or manually via the Generate Work Order action in the Condition Monitoring application. You create measurement points in the Condition Monitoring application. Each measurement point is associated with a meter. Meters are created in the Meters application. When you create a measurement point for an asset Maximo copies the measurement point to the Meters tab of the asset record. You can record readings using the Enter Meter Readings and Manage Meter Reading History actions available from the Select Action menu. Step 1 2 Action From the Start Center click Go To > Assets > Conditional Monitoring. Click ‘New Measurement Point’ to create a new record Page 29 of 32 Tivoli Maximo Asset Management – Functional workshop 3 Enter details as shown here, ASSET – ‘AHU-100’ METER – ‘TEMP-C’ Upper Warning Limit – 45 C Upper Action Limit – 50 C Upper Limit Job Plan – JP-XXMON 4 5 Exercise - 007 Lower Warning Limit – 45 C Lower Action Limit – 50 C Lower Limit Job Plan – JPXX-MON Save the record Click ‘New Row’ on measurement section. Enter first meter reading as ’24 C’. Page 30 of 32 Tivoli Maximo Asset Management – Functional workshop Exercise - 007 6 Click Select Action -> Generate Work Order 7 System will display the following message as meter reading 24 is well within the range defined. 8 Now, enter a new meter reading as 52 Page 31 of 32 Tivoli Maximo Asset Management – Functional workshop 9 Exercise - 007 Repeat step 6Click Select Action -> Generate Work Order 10 This time, system will generate a workorder as new meter reading [52 C] is outside the threshold limit. 11 Navigate to the meter now, and verify the assets, conditional monitoring details. This conditional monitoring feature can be used to monitor the systems in a complete automated environment. Let’s discuss some scenarios of it’s use in class. Page 32 of 32