Periodic and Usage-Based Maintenance

COSMO Process Manufacturing supports two types of preventive maintenance: periodic and usage-based maintenance. The goal of preventive maintenance is to prevent failures before they happen and improve asset performance.

There are two ways in which maintenance orders are processed:

  • Periodic Maintenance, also called time-based maintenance, refers to routine maintenance tasks performed on an asset at fixed time intervals. Maintenance is calculated based on the posted maintenance date and a date interval, for example, six months after the last maintenance date.
  • Usage-based Maintenance is triggered by the actual utilization of work center. Maintenance is calculated based on the output quantity of the last maintenance and a quantity interval, for example, after 12000 units have been produced by the machine.

Settings for both types of maintenance processing are defined in the General FastTab of the Maintenance Template page. The fields are described in the following table.

Field Group Field Description
Periodic Maintenance Last Maintenance Date Specifies the date when the last maintenance was performed. The date can be updated with the maintenance date of a maintenance order when finishing.
Maintenance Interval Specifies the date formula for calculating the next maintenance date of the maintenance order template.
Next Maintenance Date Specifies the date when the next maintenance should be performed.
Usage-based Maintenance Output Quantity Specifies the current output quantity in base units of measure of the work center entered in the Work Center No. field.
Last Maintenance (Qty.) Specifies the quantity when the last maintenance was performed. The quantity can be updated with the maintenance quantity of a maintenance order when finishing.
Maintenance Interval (Qty.) Specifies the quantity interval for calculating the next maintenance quantity of the maintenance order template.
Next Maintenance (Qty.) Specifies the quantity when the next maintenance should be performed.

Periodic Maintenance

Periodic Maintenance is a time-based series of activities performed to maintain the operation of machines.

To set up periodic maintenance

  1. Choose the Lightbulb that opens the Tell Me feature icon, enter Maintenance Templates, and then choose the related link.
  2. Choose the New action.
  3. Fill out the fields on the left side of the General FastTab as described in Maintenance-/Setup Job Type.
  4. In the Periodic Maintenance field group, enter the date interval for maintenance in the Maintenance Interval field.
  5. The Next Maintenance Date field is updated based on the Starting Date + Maintenance Interval. Update this date as needed.
  6. Enter the maintenance and production information in the Lines and Manufacturing FastTabs.
  7. In the Status field, choose the Released option.

To process periodic maintenance

  1. Choose the Create Maintenance Order action.
  2. Choose the Yes button to create the maintenance order on the date specified in the Next Maintenance Date field. This date is set as the Starting Date on the new maintenance order.
  3. Update the fields in the General FastTab.
  4. In the Status field, choose the Released option.
  5. In the Maintenance Date field, enter the date the maintenance was performed.
  6. Fill in other fields and complete other processes as needed.
  7. In the Status field, choose the Finished option.
  8. Choose the Yes button to update the Last Maintenance Date field in the Maintenance Template to the date specified in the Maintenance Date field.
  9. Choose the Post action and then choose the Yes button to finalize the maintenance order.

To check the maintenance template

  1. Open the Maintenance Template page.
  2. Notice that the:
    • Last Maintenance Date field is updated with the Maintenance Date from the Maintenance Order.
    • Next Maintenance Date field is updated based on the Last Maintenance Date + Maintenance Interval.

Usage-based Maintenance

Usage-based maintenance, also called counter-based or tool/insert maintenance, refers to the cleaning and repairs that are needed to keep a tool/insert in the best working order. Maintenance is performed on usage over the life of the tool/insert.

In COSMO Process Manufacturing, you can create maintenance orders based on usage of Tool/Insert and Work Center. The usage is specified corresponding to total output quantity of Tool/Insert and Work Center. A next point of maintenance is calculated based on the quantity of the last maintenance and a quantity interval. It is possible to perform a batch operation to identify tools that need to have a maintenance order and create these orders.

To set up usage-based maintenance

  1. Choose the Lightbulb that opens the Tell Me feature icon, enter Maintenance Templates, and then choose the related link.
  2. Choose the New action.
  3. Fill out the fields on the left side of the General FastTab as described in Maintenance-/Setup Job Type.
  4. In the Usage-based Maintenance field group, enter the output quantity interval for maintenance in the Maintenance Interval (Qty.) field.
    The Next Maintenance (Qty.) field updated with the same value.
  5. Enter the maintenance and production information in the Lines and Manufacturing FastTabs.
  6. In the Status field, choose the Released option.

To process usage-based maintenance

  1. In a Production Journal or Output Journal, post output for the work center relating to the Maintenance Template.
  2. If the output exceeds the quantity entered in the Next Maintenance Qty field, then a new maintenance order is automatically created from the maintenance template.
  3. Open the Maintenance Template.
  4. Notice that the Output Quantity field is updated with the posted output. Choose the value in the field to see the Capacity Ledger Entries.
  5. Choose the Created Maintenance Orders action.
  6. On the Related menu, choose Order > Card to open the maintenance order.
    The maintenance order opens using the work date for all dates and the posted output is transferred to the Output Quantity field.
  7. Update the fields in the General FastTab.
  8. In the Status field, choose the Released option.
  9. In the Maintenance Quantity field, enter the quantity when the maintenance was performed. This can be the same as or different than the indicated Output Quantity.
  10. Fill in other fields and complete other processes as needed.
  11. In the Status field, choose the Finished option.
  12. Choose the Yes button to update the Last Maintenance (Qty.) field in the Maintenance Template to the output quantity specified in the Maintenance Quantity field.

To check the maintenance template

  1. Open the Maintenance Template page.
  2. Notice that the:
    • Last Maintenance (Qty.) field is updated with the Maintenance Quantity from the Maintenance Order.
    • Next Maintenance Date field is updated based on the Last Maintenance (Qty.) + Maintenance Interval (Qty.).

See Also

Confirmation and Posting

Feedback

Submit feedback for this page .