Forecasting MFG EAM Advisor Webcast 2015 0319

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Oracle Advisor Webcast
Use of Forecasting in Enterprise Asset
Management (eAM)
Zar Ahmed
Senior Principal Technical Support Engineer
March 19, 2015

Objectives
• Overview of Forecasting in EAM
• Understand required setup steps
• Understand the business process
• Discuss any known issues

Agenda
1 Overview of Forecasting
2 Setups Required for Forecasting
3 Process Flow Using Examples
4 Useful Additional information
5 Q&A

OVERVIEW
• 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.

OVERVIEW
• Preventive Maintenance
– 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.

OVERVIEW
• Requirements :
– 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 created 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)

OVERVIEW
• Business Process :
– 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
can generate forecasts and see what work orders are suggested. This is
required for planning purposes. These WOs can then be implemented.
SETUPS
• 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.

SETUPS
Create an Asset :

SETUPS
Create the Activities :

SETUPS
Create the Activity BOM :

SETUPS
Create the Activity Routing :

SETUPS
Link the Asset to the related Activities :

SETUPS
Create a Meter (unless you want to use a date rule) :

SETUPS
Create a Meter (continued) :

SETUPS
Create a Preventive Maintenance Schedule :

SETUPS
Last Service Details :

SETUPS
Specify any Suppressions :

SETUPS
• 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.
Forecasting Business Process :
Launch Maintenance Workbench :

1. Select Forecasting Window.
2. Enter horizon , select set name and select parameters.

3. Combine with defaults is unchecked otherwise all default PM schedules for the asset will be considered regardless of the set name.

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)

Or Click Run to see suggested (forecasted) work orders that you may
implement (note the suppressed activity in Jan 2016):

Select a longer horizon period and re-run – page 1 :

....... page 2 :

Implement work orders from the original forecast :

1. Either select specific work order and click implement
2. Or click select all button and click implement

If forecast is re-run, the system recognizes that a work order exists :

View the created work order summary from Work Orders Window on MWB :

Open the Work Order if required from MWB :

Check material requirements if required :

Check labor requirements if required :

Release the work order using the Mass Release button :

Work Order is now released :

1. Issue materials to WO
2. Carry out the work – enter resource transactions.
3. Complete Work Order – enter meter reading – PM last serv date updated

Meter Rule Calculations :
• The scheduling options on PM include various date options (actual and scheduled 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)
• 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

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.
• Let’s 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

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.

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

DATE RULES :

Additional Example :
•Three Activity Example:
• Inspection every 100 hours of operation
• Minor PM for every 200 hours of operation
• Major PM for every 400 hours of operation
• Scheduling Option: Base Meter

PM Schedule for this additional example :

Forecast for this additional example:

Useful information for this additional example :
• 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.

FORECASTING IGNORES THE CALENDAR! :
• 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.

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.
• 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.
Additional Useful Information
• NEXT WO Only field on PM Schedule

– 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.
– No : 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.

Additional Useful Information
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'

Summary
What we covered today
Overview of Forecasting
Looked at setups required
Look at the process flow using
some examples.

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Q&A
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Top Articles and Community Links
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ATTENTION – AUDIO Options

Option 1: Voice Streaming Audio Broadcast Option 2: Teleconference (Dial In)

Upcoming: Use of Forecasting in Enterprise Asset Management (eAM)

 Check out Note ID : 740966.1

 Select your Product Area

 Scan through the list of Current Topics

 Register for the session(s) of your interest

Upcoming: Use of Forecasting in Enterprise Asset Management (eAM)

Copyright © 2015 Oracle and/or its affiliates. All rights reserved. | 4

March 19, 2015

Copyright © 2015 Oracle and/or its affiliates. All rights reserved. | 5

• Overview of Forecasting in EAM

• Understand required setup steps

• Understand the business process

• Discuss any known issues

Copyright © 2015 Oracle and/or its affiliates. All rights reserved. | 6

Copyright © 2015 Oracle and/or its affiliates. All rights reserved. | 7

• Two ways in which Work Orders are raised in eAM

• PM Work Orders are created in two ways :

Copyright © 2015 Oracle and/or its affiliates. All rights reserved. | 8

Copyright © 2015 Oracle and/or its affiliates. All rights reserved. | 9

Copyright © 2015 Oracle and/or its affiliates. All rights reserved. | 10

• The key setups are :

Copyright © 2015 Oracle and/or its affiliates. All rights reserved. | 12

Copyright © 2015 Oracle and/or its affiliates. All rights reserved. | 13

Copyright © 2015 Oracle and/or its affiliates. All rights reserved. | 14

Copyright © 2015 Oracle and/or its affiliates. All rights reserved. | 15

Copyright © 2015 Oracle and/or its affiliates. All rights reserved. | 16

Copyright © 2015 Oracle and/or its affiliates. All rights reserved. | 17

Copyright © 2015 Oracle and/or its affiliates. All rights reserved. | 18

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Copyright © 2015 Oracle and/or its affiliates. All rights reserved. | 21

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2. Enter horizon , select set name and select parameters.

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• Forecasting IGNORES the calendar setups! Hence, work

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• This is a parameter on the EAM Parameter form.