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How to stop unwanted triggering of work orders for performance based maintenance plan?

Dear fellows,

I have scheduled a performance based maintenance plan based on running hours. I updated the measuring document with the current running hours of each equipment. The trouble is maintenance orders are getting generated even without the counter hitting the set point frequencies/running hours.

For eg. One of my equipment is at 2 running hours. The maintenance task list does not have a maintenance scheduled at 2H. However, the system is triggering work orders.

I read somewhere that this is due to annual estimate of the running hours and incorrect setting of dead line monitoring.

Can some one explain how to rectify this fault and properly set the dead line monitoring?

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5 Answers

  • Apr 12, 2018 at 02:42 PM

    Hello James,

    Annual estimate functions as below,

    Say for example you have a counter with annual estimate 360. That means on average this counter runs 1 unit every day. (360/360).You create a perf. based. maint. plan to this counter and set a cycle of 2 unit. Then you enter a measuring document and schedule the maint. plan. 2 days later, if you do not create any measuring document, even with 0 difference, when you schedule the plan system will generate a call since you define your annual estimate as 360. If you create measuring document with 0 difference then no call will be generated. This is the standard behavior and I am sure that you can find a lot of blogs, posts about it. For example check this one:

    You have two options to discard the functionality

    1- Make sure that you create measuring document every once in a while, (every day or every week) even there is no actual difference in reading.

    2- Define an unrealistic annual estimate value so that no geneartion is possible due to low annual estimate. Like 10 units per year.

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  • Apr 19, 2018 at 07:56 AM

    Hi Suleyman,

    Thanks for your detailed answer. Appreciate your time and expertise so much!!

    I am following a strategy plan (IP40) for perf. based maint. plan and not a single cycle plan. Hence, I have a task list with frequencies set at different running hours based on the manual. Do you have any idea how the dead line monitoring works?

    My understanding of your answer is:

    If I change my maintenance plan now (IP02) and alter my annual estimate from 3000RH to an unrealistic value like 10 , then the issue won't repeat.

    If I update the measuring document every week, then the issue will be resolved but this is tough work and can be forgotten easily. Can this be automated?

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    • Hi James,

      In Deadline montoring (IP30) is the Interval for Call Objects are maintained ? If you have maintained any specific value, system will call the orders within that period.

      For Performance Based Plans, there is no issues on when you are entering the documents, but system will trigger the order when the particular counter is reached.

      Annual estimate is a trigger to understand when the call object is called for the scheduling period. For a year it will be 365*24 = 8760 hrs. For a 3000RH package, every 125 days, you will get a order. If your Annual estimate is less than or more, the dates will be changed accordingly

      In your case, check the Maintenance Scheduling, check the next counters it has planned to call the order. If this has strategy, you need to check whether the correct package is assigned and it is picked.

      You can share screenshots of Plan / scheduling parameters / scheduling overview / Packages assigned in plan etc, so we can also check and update you.



  • Apr 24, 2018 at 10:44 AM

    Dear Maria,

    I have all the pictures you need. For some strange reason, I am not able to complete the upload function on this forum. Can I send this to your email address instead?

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    • Hi James,

      I checked your screenshot, some thing strange on maintaining the measurement documents.

      Is it reverse counter ? Completed Counter reading is 250 - 48 = 202 ?

      With respect to your scheduling parameters, If the First call is generated on 12.07.2018, next call will be 50Hr (50/8=6.25) which is 6 days from first call, it is 18.07.2018.

      Annual estimate is used to calculate your plan dates and call dates, this should be realistic else you will not understand how often you need to do maintenance etc. In your case, i have a doubt on counter measurement documents.



  • Jun 10, 2018 at 06:41 AM

    Hi Maria,

    Task list

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  • Jun 11, 2018 at 01:00 PM

    Hi again James,

    Actually I've lost the track of questions and answers but here I have a suggestion for you. (I do not know what was Maria going to explain you with the screenshots.)

    If you can't create measurement document every once in a while you have 2 options:

    • Define realistic annual estimate Develop a program that creates measurement document with 0 change for all measuring points. Create a job for it.
    • Define unrealistic annual estimate. Then your next calls will be calculated accordingly and you won't have unwanted work orders

    For those 2 options you do not have to change anything related to IP30. Your variant seems OK.

    Now, with respect to option you are going to choose, your IP24 will be affected.

    Assuming you have just created following maintenance plan. Say for example you have packages of 500 and 1000 hours. Your annual estimate is realistic, let's say on average you do your 500 package every 3 months. Then, your annual estimate would be 2000. Your scheduling period in the maintenance plan is let's say 1 year. Today, you have a maintenance with the package of 500 hours. You have completed it today. Now, if you run IP10 or IP30 and execute IP24 for that maintenance plan, you will have 4 calls for the future:

    1st one is scheduled for 11.09.2018 (500H-1000H)

    2nd one is scheduled for 11.12.2018 (500H)

    3rd one is scheduled for 11.03.2019 (500H-1000H)

    4th one is scheduled for 11.06.2019 (500H)

    Now that makes 1 year of scheduling period.

    Let's take the 2nd option with the same parameters, but, this time your unrealistic annual estimate would be 500. You have your order due today, and you have completed it. Once you run IP10 and IP24, you will have only one call scheduled for the future:

    Only one call is scheduled for 11.06.2019 (500H-1000H)

    This is the main difference you are going to encounter. So choose according to your business requirement.

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    • Yes it will be created. Regardless of the next planned call date, since you created a measurement document that fulfills the package, there will be an order. Once it is created and completed, next planned call date will be updated again according to your annual estimate.

      Yes you can set 2H as your annual estimate.