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[ Learning Points
Creating maintenance Strategies and Packages
Using maintenance strategies in Task Lists
How maintenance strategies are used in Maintenance Plans
Real Experience. Real Advantage. 2
[ Maintenance Strategy - Definition
A maintenance strategy defines the rules for the sequence andfrequency of maintenance activities. The strategy does not provideany details about the activity, object or date.
Maintenance strategies are assigned to a task list and also amaintenance plan. Task lists built with a maintenance strategy canonly be used on maintenance plans utilizing that same strategy –these are called strategy plans.
Real Experience. Real Advantage.
these are called strategy plans.
You create a maintenance strategy and strategy plans when you haveto perform maintenance activities that are based on each other orsupersede each other
Strategies contain maintenance packages which define the duration intime (e.g. weeks) or level of performance (e.g. operating hours) atwhich maintenance work is repeatedly performed. Therefore,strategies are used in both time-based and performance-basedmaintenance and represent the maintenance “cycle”.
[ Maintenance Strategy – Definition (continued)
Each strategy that is created should have a common unit ofmeasure (e.g. weeks, months, hours, miles) – you should nevermix the units of measure within a given strategy.
Maintenance packages are assigned to task list operations – anddefine the frequency and sequence in which task list operationswill appear as work order operations.
Real Experience. Real Advantage.
will appear as work order operations.
Maintenance packages are organized into a maintenancepackage hierarchy that determines which maintenancepackages are performed if several maintenance packages aredue at one time. The hierarchy can either be:
Single-level hierarchy
Multi-level hierarchy
[ Maintenance Strategy Terms
Strategy Code
Description
Scheduling Indicator (Type)
Strategy Unit
Call Horizon
Real Experience. Real Advantage.
Call Horizon
Shift Factor for Late Completion
Tolerance for Late Completion
Shift Factor for Early Completion
Tolerance for Early Completion
Factory Calendar
[Scheduling ParametersStrategyScheduling Type
Activity TypeActivity TypeActivity TypePackages
Settings can be established at the strategylevel and they will carry over to eachindividual maintenance plan when it iscreated.
Maintenance Strategy vs Scheduling Parameters
Real Experience. Real Advantage.
[ Comparing Maintenance Strategy to Plan
Strategy Field Changeable or Fixed in Plan
Scheduling Indicator (Type) Limited (can change between 3 typesof time based) (Cannot changebetween time based and performance)
Strategy Unit Fixed – No changes on Plan
Real Experience. Real Advantage.
Call Horizon Changeable on Plan
Shift Factors Changeable on Plan
Shift Tolerances Changeable on Plan
Factory Calendar Changeable on Plan (only on key dateand factory calendar plans)
[Scheduling ParametersStrategyScheduling Type
Activity TypeActivity Type
Activity TypePackages
Scheduling Types•Time-Based
•E.g. – Every 30 calendar days
•Does NOT take into account the factory calendar
•Time-based by key date
•E.g. – Every 30 days do on the 28th of each month
Maintenance Strategy - Scheduling Type
Real Experience. Real Advantage.
•E.g. – Every 30 days do on the 28th of each month
•Time based – factory calendar
•E.g. – Every 30 working days, Option for seasonality
•Performance based
•E.g. – Every 100 Operating hours, 50,000 tons of coalthrough, xxxx units made, etc.
[Scheduling ParametersStrategyScheduling Type
Activity TypeActivity TypeActivity TypePackages
Scheduling Typeand Parametersdefined atStrategy Level
Strategies & Packages maintained within IP11
Maintenance Strategies & Packages (Cycles)
Real Experience. Real Advantage.
Time Based Strategy Packages
Performance Based StrategyPackages
Strategy Level
[Scheduling ParametersStrategyScheduling Type
Activity TypeActivity TypeActivity TypePackages
Settings can be established at the strategylevel and they will carry over to eachindividual maintenance plan when it iscreated.
Unit defines time basis on which schedulingcalculations are made. Use same Unitwithin a Strategy.
Once the strategy unit is created it can’t bechanged.
Maintenance Strategy – Unit of Measure
Real Experience. Real Advantage.
[Scheduling ParametersStrategyScheduling Type
Activity TypeActivity TypeActivity TypePackages
Call Horizon – Percent of the next cycle thesystem waits before the next call object is created
Call horizon determines when a maintenancecall object (e.g. Work Order, Notification) shouldbe generated. If the duration of the cycle is 360 days and the call
horizon is 0 %, 80%, or 100%, the system createsthe order after the following number ofdays:
• 0% -> Immediate call (order created 360 days
Maintenance Strategy – Call Horizon
Real Experience. Real Advantage.
• 0% -> Immediate call (order created 360 daysBEFORE plan date)
•80% -> Call after 288 days, that is 80% of 360days or creation of order 72 days before plan date.
•100% -> Call after 360 days, on the planned date(can work well if coordinated with IP30 Call Interval)
Call horizon is defined in percentage termson Strategy or individual Maintenance Plan
[Call Horizon – Example – Plan with 30 Day Cycle
100% HorizonCall & Plan Dates aresame
50% HorizonCall Date is 15 Daysbefore Plan
Scheduling ParametersStrategyScheduling Type
Activity TypeActivity TypeActivity TypePackages
SAP Maintenance Strategy – Call Horizon
Real Experience. Real Advantage.
0% HorizonCall Date is 30 Daysbefore Plan
[Shift Factors & Tolerance
Tolerance defines the period within which late or early completion impacts subsequent scheduling of Plan. (+)Tolerance is set for late completion and (–) Tolerance for early completion.
If completion is within Tolerance period it is not considered late or early and does not impact schedule.
Cycle Cycle
Tolerance (+)(- )Tolerance
PlanDate
PlanDate
PlanDate
Scheduling ParametersStrategyScheduling Type
Activity TypeActivity TypeActivity TypePackages
SAP Maintenance Strategy - Shift Factors / Tolerances
Real Experience. Real Advantage.
Tolerance (+)(- )Tolerance
30 Day
6 Day 6 Day
30 Day
If completion is out-with Tolerance period it will impact schedule taking account of Shift Factor values
Tolerance is defined as percentage ofcycle (for Strategy Plans it takes smallestperiod).
As shown here a 20% tolerance results in12 Day Tolerance window (6 Days oneither side of Planned Date).
[Shift Factors & Tolerance
The Shift Factor applies in event of late or early completion of Maintenance Task (Call Object).
It defines how much subsequent schedule dates will be changes as result of later or early completion.
Cycle Cycle
PlanDate
PlanDate
PlanDate
Early ActualCompletion
Late ActualCompletion
Scheduling ParametersStrategyScheduling Type
Activity TypeActivity TypeActivity TypePackages
SAP Maintenance Strategy/Plan - Shift Factors/Tolerances
Real Experience. Real Advantage.
30 Day Cycle
8/1/2007
ActualCompletion8/24/2007
8/31/2007 9/30/2007
- 7 D
9/23/2007
- 7 D
OriginalPlanDate
NewPlanDate
100% Shift Factor, 20%Tolerance (6 days)
30 Day Cycle
8/1/2007
ActualCompletion8/25/2007
8/31/2007 9/30/2007
-6 D
OriginalPlanDate
0% Shift Factor, 20%Tolerance (6 days)
No ChangeTo Plan Date
[
Shift Factors & Tolerance
Scheduling ParametersStrategyScheduling Type
Activity TypeActivity Type
Activity TypePackages
SAP Maintenance Strategy/Plan - Shift Factors/Tolerances
Real Experience. Real Advantage.
30 Day Cycle
8/1/2007
ActualCompletion8/24/2007
8/31/2007 9/30/2007
- 7 D
9/27/2007
- 3 D
OriginalPlanDate
NewPlanDate
50% Shift Factor, 20%Tolerance (6 days)
[Scheduling ParametersStrategyScheduling Type
Activity TypeActivity TypeActivity TypePackages
• Cycle length
• Unit of Measure – same as strategy unit
•Cycle abbreviation
SAP Maintenance Strategy – Packages
Real Experience. Real Advantage.
[Scheduling ParametersStrategyScheduling Type
Activity TypeActivity TypeActivity TypePackages Lead and Follow up Float
• Can only set on Strategy and not on individual Plans (not applicable to Single Cycle Plans).
• If change is made to float within Strategy you need to reassign Task List to Plan and RestartPlan schedule.
SAP Maintenance Strategy – Package Lead/Follow up Float
Real Experience. Real Advantage.
• The Initial (Lead) Float, defined in days, adjusts the Basic Start Date on Work Order.
• The Subsequent (Follow up) Float, defined in days, adjusts the Basic End Date on Work Order.
[Lead and Follow up Float - Example
Basic Start and End Dates oncalled Work Order reflect the Floatperiods
Scheduling ParametersStrategyScheduling Type
Activity TypeActivity TypeActivity TypePackages
SAP Maintenance Plan - Package Lead / Follow up Float
Real Experience. Real Advantage.
-10+1
-10+2
[Multi-Level Hierarchy
Package Hierarchy value determinesplace in hierarchy and is used to controlpriority of packages with the same due(planned) date.
If packages with same due date are to
Scheduling ParametersStrategyScheduling Type
Activity TypeActivity TypeActivity TypePackages
SAP Maintenance Plan – Package Hierarchies
Real Experience. Real Advantage.
If packages with same due date are tobe called then they must have samehierarchy number.
If packages have different hierarchynumbers then only the package withhighest number is called.
[Single-Level Hierarchy
Scheduling ParametersStrategyScheduling Type
Activity TypeActivity TypeActivity TypePackages
SAP Maintenance Plan - Package Hierarchies
Real Experience. Real Advantage.
In this case 3M and 1Y arecalled with 1M.
[ Maintenance Strategy – Time w/Hierarchy Monthly Units
Hierarchies
Real Experience. Real Advantage.
Hierarchies
Advantages: Can coordinate single operation orders simplifying scheduling and time entry
Disadvantages: More text and duplicate text per operation
[ Task List – Strategy Options with Same Results
Strategy w/Hierarchy Packages Only – Single package allocation
Strategy w/Hierarchy Packages Only - >1 package allocation
Above Model results in duplication of text
Real Experience. Real Advantage.
Strategy w/Hierarchy Packages Only - >1 package allocation
Strategy w/no hierarchies - >1 Package allocation
[ Strategies with and without Package Hierarchies
Packages without Hierarchy Packages with Hierarchy
It is possible to have strategies with packages that contain hierarchies and nohierarchies – This can be confusing.
Real Experience. Real Advantage.
Packages with and without Hierarchy
[
With this Offset both 3 Monthlyand Yearly packages will be
Scheduling ParametersStrategyScheduling Type
Activity TypeActivity TypeActivity TypePackages
SAP Maintenance Plan – Packages – Package Offset
Real Experience. Real Advantage.
and Yearly packages will becalled 1st Cycle (Month)
With this Offset both Yearlypackage will be called 3rd Cycle(Month)
[
Package Offset
Scheduling ParametersStrategyScheduling Type
Activity TypeActivity TypeActivity TypePackages
SAP Maintenance Plan – Package Offset
Real Experience. Real Advantage.
With this Offset 3Monthly will becalled 2nd Cycle and Yearly willbe called 3rd Cycle (Month)
[ Task Lists - Supporting Maintenance Plans
Strategy Plans must
Task Lists applied in same way to Strategy, SingleCycle or Multiple Counter Plans
Real Experience. Real Advantage.
Strategy Plans musthave same Strategyon Task List, Itemsand Plans
Strategy plansMUST have a tasklist or will notschedule plan, willhave “Error”.
[ Task List – Assigning Packages
Strategy w/Hierarchy Packages Only – Single package allocation
Strategy w/Hierarchy Packages Only - >1 package allocation
Real Experience. Real Advantage.
Strategy w/no hierarchies - >1 Package allocation
[ Maintenance Strategy w/no Hierarchy
Real Experience. Real Advantage.
When work orders are then generated from the maintenance plans that use the task lists.The task list operations then become the work order operations. Because they are organizedin a single-level hierarchy, the operations will not supersede each other. In other words:
Operation 10 (check fluids) will come out every 2000 miles – even when Operation 20 (change oil)and Operation 30 (rotate tires) are also due
Operation 20 (change oil) will come out every 4000 miles – even when Operation 30 (rotate tires) isalso due
Operation 30 (rotate tires) will come out every 6000 miles – regardless of
other operations that are also due
[ Maintenance Strategy – w/Hierarchy
Real Experience. Real Advantage.
When work orders are then generated from the maintenance plans that use the task lists.The task list operations then become the work order operations. Because they are organizedin a multi-level hierarchy, the operations with a higher hierarchy number will alwayssupersede operations with a lower hierarchy number. In other words:
Operation 10 (check fluids) is due every 2000 miles, but it will only come out on the work orderwhen package 2 is the only one due
Operation 20 (check fluids, change oil) is due every 4000 miles. It will always supersede Operation10 because it has a higher hierarchy number.
Operation 30 (check fluids, change oil, rotate tires) is due every 6000 miles. It will always supersedeOperation 10 and Operation 20 because it has a higher hierarchy number.
[ Maintenance Plan – Strategy Plans – Time Based A time-based strategy plan should be used when:
Preventive maintenance activities are triggered when a certain time limitis reached
Maintenance activities (task list operations) change depending on thefrequency that is due – in other words, the maintenance activities arebased on each other or supersede each other
The time-based strategy plan consists of: Maintenance plan
Real Experience. Real Advantage.
Maintenance plan
Maintenance items (one or more)
Task list
Maintenance strategy
Task lists are required for time-based strategy plans
The strategy referenced on the maintenance plan must matchthe strategy used to build the task list attached to themaintenance items.
[ Maintenance Plan – Strategy Plans – Performance Based A performance-based strategy plan should be used when:
Preventive maintenance activities are triggered by a counter reading
Maintenance activities (task list operations) change depending on the frequencythat is due – in other words, the maintenance activities are based on each otheror supersede each other
The time-based strategy plan consists of:
Maintenance plan
Maintenance items (one or more)
Task list
Real Experience. Real Advantage.
Task list
Maintenance strategy
Measuring point (counter)
Measurement documents (on-going transactional data)
Task lists are required for performance-based strategy plans
The strategy referenced on the maintenance plan must match the strategyused to build the task list attached to the maintenance items.
Readings must be taken on a consistent basis for the plan to functioncorrectly.
[ Preventive Maintenance – Performance Strategy no Hierarchy
Net operation count result:
Multiple operations per orderfor certain cycles.
Real Experience. Real Advantage.
When work orders are then generated from the maintenance plans that use the task lists.The task list operations then become the work order operations. Because they are organizedin a single-level hierarchy, the operations will not supersede each other. In other words:
Operation 10 (check fluids) will come out every 2000 miles – even when Operation 20 (change oil)and Operation 30 (rotate tires) are also due
Operation 20 (change oil) will come out every 4000 miles – even when Operation 30 (rotate tires) isalso due
Operation 30 (rotate tires) will come out every 6000 miles – regardless of other operations
that are also due
[ Preventive Maintenance – Performance Strategy with Hierarchy
Net operation count result:
Always single operation for allwork orders
Real Experience. Real Advantage.
When work orders are then generated from the maintenance plans that use the task lists. The task listoperations then become the work order operations. Because they are organized in a multi-levelhierarchy, the operations with a higher hierarchy number will always supersede operations with a lowerhierarchy number. In other words:
Operation 10 (check fluids) is due every 2000 miles, but it will only come out on the work order when package 2is the only one due
Operation 20 (check fluids, change oil) is due every 4000 miles. It will always supersede Operation 10 because ithas a higher hierarchy number.
Operation 30 (check fluids, change oil, rotate tires) is due every 6000 miles. It will always supersede Operation 10and Operation 20 because it has a higher hierarchy number.
[ Key Learnings
Creating maintenance Strategies and Packages
Using maintenance strategies in Task Lists
How maintenance strategies are used in Maintenance Plans
Real Experience. Real Advantage. 40
[
[
Thank you for participating.
SESSION CODE:
Please remember to complete and return your
evaluation form following this session.
For ongoing education on this area of focus, visit the
Year-Round Community page at www.asug.com/yrc
Mark W. Scottmscott @vestapartners.com
Real Experience. Real Advantage. 41
[ SESSION CODE:
2612