Performance based preventive maintenance

[sanjay_nanda4]

Hi Team,

I want to do performance based preventive maintenance of my equipment.(pump).I need to do

performance based preventive maintenance of my pump as follows:

My operations of pump are as follows:

1: Oil leakage checking after every 1000gph(gallon/hr)flow rate.

2: Pump motor base bolts checking after 2000gph(gallon/hr)flow rate.

Flow rates of the pump are not constant. It is irregular.For example if today's flow rate say 100gph and tomorrow it is 150gph and so on.

So if i enter my measurement documents(IK11) against the counter for the respective flow rates and when the flow rate will reach 1000gph or 2000gph it will creat maintenance order.

So my question is why it is needed to schedule through IP10/IP30 for my maintenance plan(IP42).If the flow rate is constant for every day then it is meaningful

to do scheduling.

In my case it is irregular. So without scheduling my maintenance plan through IP10/IP30) i can generate maintenance order(IW31) automatically in the

background by continously updating readings through measurement documents(IK11).

Do you think that in my case it is needed to be scheduled(IP10/IP30)?

Kindly help.Need good explaination.

Regards

Sanjay

[sebastian_lenartowicz]

Greetings Sanjay,

TMM, you will nevertheless need to use IP30/IP10 scheduling to call the orders. You may use a high Call horizon setting in your Maintenance Plan scheduling parameters (95-100%) to prevent the PM Orders from being generated too early.

What SAP PM will do is to determine call and due dates in the scheduling period for a counter-based plan based off the Measurement documents entered and the Annual estimate on the Measuring point (counter).

If e.g. your flow was (roughly on average!) 1000 gallons per day, then your Annual estimate would be 365000 gallons. Then if you had a scheduled inspection after say 60000 gallons of flow, SAP would schedule in after 2 months. But say on days 1. to 5. you had an average flow of 1000 gallons a day. Up till that point you'd register 5000 gallons total flow and your schedule wouldn't change, since you're following the Annual estimate. Then on days 6 to 9 you had an upsurge in flow of 1500 gallons per day. You'd end up measuring 2000 gallons more flow than expected 9000, so your scheduling would shift two days (difference divided by your estimated daily flow) earlier. Then for next five days the pump was disengaged and you didn't register any flow, but you still kept creating Measurement documents with a reading of 11000 and difference of 0. SAP PM would reschedule your maintenance a day later for each day of outage automatically.

Hence it is important that your Measurement documents are input regularly to enable SAP PM to reschedule your maintenance effectively.

What I am a bit surprised of is that you write about measuring flow rate (gallons per hour) instead of flow (gallons). I would expect flow to be captured on a counter, flow rate would be registered on a measuring point as it does not add to a total, but is momentary.

[former_member214626]

Hi Sanjay ,

As others said ,Creating order immediately after posting the measurement document is not possible with standard SAP . In standard you have to schedule your plans .

For performance based plans , IP30 will serve the purpose in best way . One thing you can do is while scheduling performance you can keep the  timings for background job to very minimum value (say every 2-3 hours ) but dont forget to use sort field value in IP30 while making it as a background job . This sort field value will help system to restrict the scheduling for only performance based plans .

Note : Sort field is entered in Plan . You can decide a particular sort field value and enter it in every performance based plan .

Regards

[Former Member]

Hi Sanjay,

To add to Maheswaran's input above, performance base preventive maintenance is based on throughput (# of gallons pumped, # of km run, # of hours of operation) and in creating the measuring point, you have to provide the estimated annual consumption, this value in turn will be interpreted by SAP as the basis of calculating the planned dates of the Maintenance Orders.

Entering measurement documents in the system allows recalculation of the planned date of the next order and running IP10 manually or creating the background job for IP30 creates this order automatically depending on the call horizon that you set up.

I hope i was able to provide additional information.

regards.

[Former Member]

While updating the Measurement document, creating Maintenance order automatically is not possible in standard. You have to use some user exit to trigger that.

The same functionality has been given by using maintenance plan scheduling in IP10 / IP30. IP30 background job can be run on daily basis to create maintenance order, so that system will check on daily basis & order will be created based on that.

I hope I have given good explanation.

[sanjay_nanda4]

Hi Maheswaran,

I guess your explaination is justified.I want to clarify one thing from you.Whether you run IP10 or IP30,

system will check total counter reading in IP10 screen which is updated after every mesurement document and when the order is due it will generate maintenance order automatically.Therefore

IP10 is necessary whether you run manually or you call it through batch job(IP30)

One more question if your pump flow rate is equal on each day then based on annual estimate

it will generate maintenance order when it is due.In this case also we have to enter measurement documents even if they are same on every day.Correct me if i am wrong.

Waiting for your reply.

Regards

Sanjay

[Former Member]

Even you run IP30 directly, scheduling will consider the measurement document reading only. If no measurement document is available, then it will check for annual estimate.

Our presumption is that flow rate is same always. May be in reality, it will not be the case. So it's like going based on assumption (annual estimate) or actual (measurement document).