Oracle Enterprise Asset

Management
Use of Forecasting in
EAM
An Oracle White Paper
May 2015

Table of Contents
1. OVERVIEW OF FORECASTING ............................................................................................................................................................................................. 1
2. SETUPS REQUIRED FOR FORECASTING ............................................................................................................................................................................. 3
3. PROCESS FLOW USING SOME EXAMPLES .......................................................................................................................................................................... 9
4. METER RULES AND DATE RULES......................................................................................................................................................................................17
5. USEFUL ADDITIONAL INFORMATION ..............................................................................................................................................................................22

1. OVERVIEW OF FORECASTING
There are two ways in which Work Orders are raised in eAM

Manually created in Forms or Self Service

Automatically created Preventive Maintenance (PM) Work Orders

PM Work Orders are created in two ways :

Generate Preventive Maintenance Work Orders Concurrent Program.

This generates the work orders in unreleased status. Then you can
choose the implement button from Maintenance Workbench to
release the work orders.
Forecast Work Orders in Maintenance Workbench > Then create these
using the implement button.

Preventive Maintenance provides the features below:

Reduces the probability of failure or degradation of assets

Ensures that maintenance work is done on a timely basis
The work orders are automatically raised based on meter readings,
run time intervals and calendar days.

The requirements for setting up Preventive Manitenance are :

Activities are created for the work required on an asset. You can
associate a Bill of Materials (BOM) and a routing to the activity.
Meters are created to allow rules to be specified for generating work
orders based on certain readings (e.g a service every 15000 miles).
Preventive Maintenance Schedules are created for an asset to hold
the rules and criteria for generating the work orders and specify the
work required (activities).

The business process is as follows:

Once the PM Schedules are created, the Generate PM Maintenance

Work Orders Concurrent Program is scheduled to run on a regular
basis to create the work orders in a unreleased status.
One can then use the Maintenance Workbench to view these work
orders and release them using the Implement button or use Mass
Release (the PM Scheduler is launched when using implement).
Maintenance Workbench allows the following functionality also : You
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can generate forecasts and see what work orders are suggested. This
is required for planning purposes. These WOs can then be
implemented. We will look at forecasting in more detail in this paper.

2. SETUPS REQUIRED FOR FORECASTING

The key setups are :

Create an asset
Create activities for the maintenance work to be done for the asset
and optionally specify any BOMs and routings for the activities.
Create the required meters for the meter rules.
Create the PM Schedules for the requires asset/activity
combinations.

Lets look at each of these steps in more detail :

2a. The above screenshot shows the setup of an asset.

2b. The above screenshot shows an activity setup.

An activity has been defined for an oil change.

2c. The above screenshot shows the Bills Of Material definition for the
activity - i.e the materials required for the oil change.

2d. The above screenshot shows the labor routing for the oil change activity.

2e. The above screenshot shows the related activities (including the oil
change activity we have created) being linked to the asset using the Activity
Association form.

2f. The above TWO screenshots show a meter being created. Meters will be
required unless ONLY date rules will be used.

2g. Next a PM Schedule is created specifying the activities and the meter rule.

2h : the above screenshot shows the last service information which will
default when the PM schedule is created.

2i. Finally, the above screenshots shows the suppressed activities (if
required). In this, the 30000 mile service activity suppresses the oil change
activity because an oil change is done as standard as part of a 30000 mile
comprehensive service.
Notes about the scenario above:

Intervals Per Cycle field. This field represents the number of base intervals
that comprise the complete cycle. For example, 12 monthly intervals
would comprise a 1-year cycle, and six 5000 miles base intervals would
comprise a 30,000-mile cycle.
The group of maintenance activities on one PM schedule represents a
cycle of activities. After the cycle of activities completes, the cycle restarts.
For example, I can define a PM schedule for two activities that have a
common Base Interval of 5000 miles. The first activity is an oil change, and
is scheduled every 5000 miles.
The second activity, a major service , is scheduled for every sixth interval
or 30,000 miles.
The work order for the oil change generates on each occurrence of the
5000 mile interval and the work order for the major service generates on
the sixth interval occurrence and suppresses the oil change because this is
done as part of the major service.

3. PROCESS FLOW USING EXAMPLES

The following business process describes the Forecasting process flow :

The above screenshot shows the Maintenance Workbench. Select the criteria
for the assets that you wish to work with and then click the Launch button.

The above screenshot shows the following actions have been taken :
Select Forecasting Window.
Enter horizon , select set name and select parameters.

Combine with defaults is unchecked otherwise all default PM schedules

for the asset will be considered regardless of the set name.

The above screenshot shows the forecasted work orders when you click
Simulate to view suggestive orders without implement option : (note the
work orders are raised every 50 days : 5000/100 = 50 and note the suppressed
activity - i.e there is no oil change activity in January because the 30000 mile
service is being done)
The simulate option is used by Planners to forecast potential orders and have
a look at what is suggested i.e, there is no implement option as this is only
used to look at what-if scenarios.

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The above screenshot shows the use of the RUN button for the same
parameters as opposed to the simulate button. Now you can see that the
implement button is available which will enable the forecasted work orders to
be actually created.
IT can be seen that the suggestions are the same as when using simulate i.e
work orders are raised every 50 days : 5000/100 = 50 and note the suppressed
activity in Jan 2016 - i.e there is no oil change activity in January because the
30000 mile service is being done.

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The above two screenshots show the outcome of a longer horizon period
being selected. You can see now that the suggested work orders are upto Feb
2017.

The above screenshot now shows the original forecast again upto Jan 2016.
We will now show how to implement a work order.

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The above screenshot shows a specific work order has been selected for
implementation (the first one we simply click the checkbox next to the work
order). You can select one or many work orders.
Alternatively, you can check the Select All checkbox and this will implement
ALL the work orders.
Then click the Implement button and a note will confirm that your work
order(s) has been implemented.

The above screenshot shows that if the forecast is now re-run, the system
recognizes that one of the work orders exists and does not require to be
created as it has already been implemented. You are simply presented with
an option to reschedule the work order.
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The above screenshot shows the work orders window on the Maintenance
Workbench and from here, you can see the work order(s) that you have
implemented. If you click on the open button in teh above screen, this will
open the work order as seen on the next screenshot below.

The above screenshot shows the work order details when opened from the
summary page.

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The above screenshot shows the materials required for the work order and
this is seen when selecting the materials button from the main work order
page.

The above screenshot shows the routing for the work order and this is seen
when selecting the Operations button from the main work order page.

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The work order summary page has a MASS RELEASE button. Clicking this
shows the screen above. You can release one , many or all work orders using
this mass release option.

The above screenshot shows that the work order is now released.

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Once the work order has been released, the following takes place :
Issue materials to the work order
Carry out the work enter resource transactions.
Complete Work Order enter meter reading once this is done, the PM
last service date is updated . The above screenshot shows the work order
completion page.

4. METER RULES AND DATE RULES

4a. METER RULES:

The scheduling options on PM include various date options (actual

andscheduled start and end dates, base date). Another option is to use
Base Meter.

If a date option is used, here is the calculation used to calculate the next
work order (in our case, we are using actual start date but the calculation
is same for the other dates). Remember that when a work order is
completed, the last service date will be updated the date field next to
the scheduling option will hold last service date) :

Actual Start Date + Base Interval*Interval Multiple/Usage Rate

9 March 2015 + 5000 * 1 / 100 (for oil change ) = 50 days (28/4/15)
9 March 2015 + 5000 * 6/ 100 (30000 ml serv) = 300 days (3/1/16)
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If you are using cycle based maintenance - Intervals per cycle, Current
Interval Count and Interval Multiple can affect the above calculation.
Imagine there are 1200 intervals per cycle, and the current interval count is
95 and the interval multiple is 40 and usage rate = 2000 . Hence, the next
WO is for 120 (because last completed cycle was 95 and interval multiple is
40).

Calculation is as follows (only because for some reason the current interval
count does not reflect the interval multiple) :

9 March 2015 + Base Interval * (Next Interval Value Current Interval

Count)/Usage Rate
9 March 2015 + 5000 * (120 95) / 2000 = 62.5 = May 12 2015

4b. USING BASE METER AS SCHEDULING OPTION :

PM Engine will not look at the work order dates and will not look at the last
service readings.

PM Engine will look at the base meter and base meter reading.

Lets look at an example :

Base Meter Reading =1

Interval = 100 (hence work orders to be suggested at meter readings of

101, 201, 301, 401, 501,601, 701, 801,901,1001 etc)
Usage Rate = 5
Latest Meter Reading = 1000 (hence the work order for 901 is due) .
Latest Meter Reading Date = 10 Oct 2014

Calculation :

Days Left = Latest Meter Reading Due Reading /Usage Rate

= 1000 901/ 5 = 19.8
WO Suggestion Date = Latest Meter Reading Date + Days Left = 10 Oct 2014 +
19.8 = 29 October 2014

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4c. HOW TO GENERATE SUGGESTIONS BASED ON METER READINGS ONLY

AND NOT ON USAGE RATE?
1. Set 'no of past readings' >999999 and 'rate per day' = 1 in meters Form.
2.Uncheck 'Implement from Horizon Start Date' parameter in eAM Parameter
window.
3.Now when you run the forecast, then suggestions falling between last
service date and latest meter reading date are forecasted with suggestion date
= sysdate.
Number of past readings is a parameter that says how many readings are
required in order to recalculate the usage rate (how many readings from the
past are used in the formula). If that number of readings is never reached
then the usage rate is not recalculated. The above setup ensures that usage
rate always remains at 1 and hence the meter readings will be used to
generate the suggestions.

4d. DATE RULES

You can use a meter rule or a date or you can use BOTH.

If you use BOTH a date rule and a meter rule, then the system will simply
look at whichever rule comes first.

However, you can choose Last Due Date in the Scheduling Based On
region. In this case, even if rule 1 reaches its due reading, the service is not
scheduled until rule 2 has also reached its due reading.

The following page shows an example date rule which creates a work order
for the activity every 90 days.

The calculation is as follows - last date was 27-Nov-2014 as shown on PM.

Next Date = Actual Start Date + Base Interval*Interval Multiple
Next Date = 27/11/2014 + (1 x 90) = 25 Feb 2015

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The above screenshot shows an example date rule.

4e. THREE ACTIVITY EXAMPLE:

Suppose there are three activities and we will use the scheduling option of
Base Meter:

Inspection every 100 hours of operation

Minor PM for every 200 hours of operation

Major PM for every 400 hours of operation

The following screenshot on the next page shows the PM schedule for this
example :

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The above screenshot shows the PM schedule for the 3 activities example.

The above screenshot shows the forecast for the three activity example.
The following points should be noted for this example:

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The program will update Current Cycle and Current Interval Count when
PM work orders are completed.

For example at 210 hours of operation, two Inspection work orders and
one Minor PM work order have been generated and completed. The
Current Interval Count has been updated to (2). The Current Interval
Count provides a count within the Current Cycle, the Current Interval
Count is updated to (1) with the start of each new cycle.

The Current Cycle provides a count of the number of times a PM Set

(Inspection, Minor PM and Major PM) has been completed. In this
example, the Current Cycle remains (1), the Current Cycle will be updated
to (2) with the completion of the PM Set and the start of a new cycle.

When forecasting work orders for the next 30 days, note that the activity
"Minor PM" is not included in the forecast but the Activity "Inspection" is
included, the "Repeat in Cycle" controls if an activity will occur within a
Cycle.

For the activity "Inspection" the Repeat in Cycle is "Yes", for the activity
"Minor PM" the Repeat in Cycle is "No", the Minor PM" will be generated
once per cycle.

5. USEFUL ADDITIONAL INFORMATION

5a. CALENDARS :

Forecasting IGNORES the calendar setups! Hence, work orders will be

suggested on non-working days because forecasting is based on a 365 day
calendar.

However, when you IMPLEMENT a forecasted work order that falls on a

weekend, the system will not consider the calendar and will schedule the
work order to a working day.

5b. IMPLEMENT FROM HORIZON START DATE:

This is a parameter on the EAM Parameter form.

If this is unchecked, then the system uses the effective start and end dates
from the PM Schedule itself for the horizon period.

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If this is checked, the system will ignore all past due work orders and only
suggest work orders for the horizon dates entered on the Maintenance
Workbench Forecasting form.

5c. NEXT WO ONLY FIELD ON PM SCHEDULE:

If set to yes : PM Engine will only create next WO if previous WO has been
completed. If this WO is open, no WO will be suggested. If it is completed, ONE
WO only will be suggested.

If set to No : PM Engine will suggest ALL required WO for the specified period.

Ensure that you have defined accounting periods for the entire horizon
otherwise there will be errors in the log file and correct WOs will not be
suggested.

5d. TABLES FOR METERS AND PM SCHEDULES:

Select counter_id from CSI_COUNTERS_V where counter_name

like'&meter_name';---provide EAM meter name stored as counters in CSI table

Select * from csi_counter_readings where

COUNTER_ID = 'enter counter id here';

select * from EAM_PM_SCHEDULINGS

where name like 'enter problematic PM schedule name'

SELECT * FROM EAM_PM_SCHEDULING_RULES

WHERE PM_SCHEDULE_ID = 'Substitute schedule id here'

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Forecasting in EAM
May 2015-05-14
Author: Zar Ahmed
Oracle Corporation
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Redwood Shores, CA 94065
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of Oracle Corporation. All other product and service names
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Copyright 2003 Oracle Corporation
All rights reserved.

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