Maintenance Exercises

Master/Basic Data Hierarchy

Basic Data for Components General Data for Application Area

Master Data for IFS Applications

System Data

Equipment Management
Process Steps 1. Create a Functional Object (\Equipment\Functional Object\Functional Object Information) 2. Enter the General Tab >> Object Id, Site, Object Level, Object Type, Category, Belongs to Object, Manufacturing Date, Installation Date, Criticality, Manufacturer, Supplier 3. Enter the Spare Parts >> Site, Part No, Quantity 4. Enter Test Points >> Test Point ID, Location 5. Enter Parameters >> Test Point ID, Parameter 6. Enter Parties >> Supplier, Owner, Manufacturer

Equipment Management
Process Steps 1. Create a Serial Object (\Equipment\Serial Object\Serial Object Information) 2. Enter the General Tab >> Object Id, Site, Object Type, Part Number, Serial Number, Category, Belongs to Object, Manufacturing Date, Installation Date, Criticality, Manufacturer, Supplier 3. Enter the Spare Parts >> Site, Part No, Quantity 4. Enter Test Points >> Test Point ID, Location 5. Enter Parameters >> Test Point ID, Parameter 6. Enter Parties >> Supplier, Owner, Manufacturer

Breakdown Maintenance
Process Steps 1. Register a Fault (\Work Order Management\Fault Report) 2. Select the Directive, Maint Org, Object ID, Description, Required start and Latest completion, Discovery, Symptom and Priority 3. Save the Fault Registry and note down the WO No. 4. RMB Prepare. Work Order opens 5. Select the Work Type 6. RMB Report In Work Order 7. Enter Actual Start and Actual Completion Dates 8. RMB > Work Order Status >Finish

Exercise - Fault Report

Register a Fault on Unit 2 for your site Select the Discovery as 002 Enter the symptom as 001 Enter the Required Start & Latest Completion Date Save the Fault Check the report O&M Breakdown Report

Exercise - Fault Report

RMB Prepare (Work Order) Enter the Planning Schedule and Planning Information Enter the Work Type as REPBRK Enter the Required Start & Latest Completion Date Change the Work Order status to Released Enter the Actual Start Date and Actual Completion Date Change the Work Order status to Finished

Exercise PM Calendar Based

Register a PM action for your Motor(Functional) Register a Calendar Based generation for the motor - 6-jun-09, every 2 months Plan crafts and material for the PM action Do a calendar Generation for the week 0023 Register an Event Give an event plan for your PM action Register that the event has happened and notice the WO that is formed

Exercise - PM - Condition Based

Make sure that motor(functional) has temperature registered as one of the parameters For your PM action mention temperature as a criteria for generation with limits as 50-100 Register temperature for the functional object(motor) as 150 and perform a condition based generation. Notice the WO that gets formed Perform the above by registering a temperature of 80

Exercise PM Event Based

Register a PM action for your Motor(Functional) Plan crafts and material for the PM action Register an Event Give an event plan for your PM action Register that the event has happened and notice the WO that is formed

Exercise - PM - Standard Jobs

Create a Standard Job for Changing Bearings with crafts and material demands Create a PM action for the motor (serial) using this standard job id and notice that the craft and the material tabs get updated automatically

Exercise - Route PM actions

For the Route Monthly Maintenance, register a PM action for Radial Gate and Under Sluice Gate (find out the Object ID in the Functional Object) Register the Start Value as 0905 and Interval as 1 month Register the planned men and planned hours Enter the Jobs in the Job tab Enter the Consumables / parts required in Materials tab Note down the Maintenance Plan Carryout the Calendar Generation & Note down the Work Order Number

Exercise - Work Order Flow

Choose one of your work orders created during previous exercises. Complete the Craft and Material planning for the WO Release the WO In the /Requisition tab of WO raise a PR for one of the parts . Release the requisition

Exercise - Work Order Flow (Contd.)

Retrieve the requisition in Purchasing and convert it into a PO Plan and confirm the PO Do arrival registration for the PO Raise an invoice for the PO and post the invoice. You would notice that the cost of the invoice gets updated as the actual values in WO Open Report In WO and retrieve your WO Reserve and issue the materials In /Time Report, report a few hours for a few employees Notice the changes that are happening in the /Postings tab

Exercise - Work Order Flow (Contd.)

Once all material and time reporting are over, Go to /General tab and fill in all the relevant data Authorize all the unauthorized postings Finish the WO and notice that it appears in the Historical WO. Also notice the appearance of the data in the /Cost/year tab of the object

Exercise - Work Order Flow (Contd.)

Pick up any of your round WO Report time and material for it Create a fault report for an object from here Authorize postings and finish the WO

External Repair Process

Register a Repair Order by creating a Repair Order for Serial Object Enter the Repair Workshop as REPAIRWORKSHOP Select the Work Type that belongs to external repair Move the serial into Inventory Location at the WO Site. Create a Service Purchase Requisition (No Part Order Lines with Purchase Group for External Repair Maintenance) Release the PR and convert it into PO

External Repair Process

Send the material to the supplier through Gate Pass by registering a RMGP Send the material by Gate Out Once the material is repaired, return the material back to Inventory Issue the material in the WO Complete the Purchasing process Place the Serial back in the Equipment Structure Finish the Work order process

 Create a fault report & WO for your functional motor with spare part requirement as your serial motor. Report the WO by issuing a motor of a different serial no. from the inventory and place the serial object under the functional motor. Notice in the graphical object structure that the new motor is included in the equipment structure Create a new object RWSX - repair workshop Create a repair WO for your older serial motor and move it to the RWSX. Prepare and report the WO and move the serial object to inventory. Notice the change in the position of the serial object

Exercise Repair Work Order Flow (Contd.)