Planned Maintenance

The Enterprise Asset Management module includes the Planned Maintenance capability that enables manufacturers and distributors to digitize their asset maintenance processes by defining the maintenance requirements and planning this out into the future. This module integrates with the Requirements Planning and Purchase Orders modules to ensure timely procurement of part requirements for planned and preventative asset maintenance.

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Exploring

The Enterprise Asset Management module includes the Planned Maintenance capability that enables manufacturers and distributors to digitize their asset maintenance processes by defining the maintenance requirements and planning this out into the future. This module integrates with the Requirements Planning and Purchase Orders modules to ensure timely procurement of part requirements for planned and preventative asset maintenance.

  • Increased equipment lifespan

  • Reduced downtime

  • Cost savings

  • Improved safety

  • Enhanced efficiency

  • Improved quality

  • The Planned Maintenance capability ensures that you can establish comprehensive maintenance requirements for each asset, including specifications for spare parts and service operations. This ensures all resources are identified and available on time, streamlining the preparation for maintenance activities.

  • Maintenance activities can be scheduled efficiently to minimize downtime and enhance productivity across operations.

  • The maintenance schedule streamlines the preparation process by ensuring the availability of all information and necessary resources before maintenance begins.

  • Costs associated with maintenance activities are monitored and managed, providing valuable insight into resource allocation and budget adherence.

  • Unforeseen planned maintenance resulting from unexpected breakdowns is supported to ensure swift corrective actions and reducing overall asset downtime.

The programs related to this feature are accessed from the Program List of the SYSPRO menu:

  • Program List > Enterprise Asset Management

Enterprise Asset Management (EAM) is a comprehensive approach to managing an organization's physical assets throughout their entire lifecycle, from acquisition to disposal. SYSPRO'S Enterprise Asset Management module focuses on the activities required to effectively manage the maintenance of machinery, parts, and other equipment to maximize their value, reduce costs, and ensure they contribute effectively to the organization's goals.

Planned maintenance within the Enterprise Asset Management module refers to scheduled maintenance activities that are pre-determined and performed at regular intervals using a planned schedule. This maintenance is carried out to prevent unexpected breakdowns and ensure continuous operation, regardless of the current condition of the asset.

Unplanned maintenance within the Enterprise Asset Management module refers to maintenance activities that are performed in response to unexpected equipment failures or breakdowns. These are unanticipated events that require immediate attention to restore the equipment's functionality. Unlike planned maintenance, unplanned maintenance disrupts normal operations and often incurs higher costs due to urgent repairs and unavailability of spare parts or resources.

Setup programs

Setup Options

Equipment Code Maintenance

Equipment Type Maintenance

Service Type Maintenance

Service Structure Maintenance

Processing programs

Planned Maintenance Job Schedule

Maintenance Job Entry

Maintenance Job Issues

Maintenance Job Closure

Report programs

Maintenance Job Parts Review

Browse programs

Capex Item and Line

Query programs

Planned Maintenance Job Schedule Query

Starting

To use this feature, the following setup option(s) must be enabled:

Setup Options > Configuration > Manufacturing > Enterprise Asset Management

  • Expense accounts only
  • Equipment serial mandatory
  • Allow zero cost non-stocked components
  • Date calculation method for planned jobs

Setup Options > Configuration > Distribution > Inventory> Show Warehouses hyperlink

  • Maintenance warehouse

To use this feature, the following eSignatures must be defined accordingly in the Electronic Signature Configuration Setup program (as this allows for the various functions in the related programs):

  • EAM Add component

  • EAM Add equipment code

  • EAM Add equipment type

  • EAM Add operation

  • EAM Add schedule line

  • EAM Add schedule recurring jobs

  • EAM Add service ledger

  • EAM Add service type

  • EAM Change component

  • EAM Change component sequence

  • EAM Change equipment code

  • EAM Change equipment type

  • EAM Change operation

  • EAM Change schedule line

  • EAM Change service ledger

  • EAM Change service type

  • EAM Component resequence all

  • EAM Copy components

  • EAM Copy operations

  • EAM Delete all components

  • EAM Delete all operations

  • EAM Delete component

  • EAM Delete equipment code

  • EAM Delete equipment type

  • EAM Delete operation

  • EAM Delete schedule line

  • EAM Delete service ledger

  • EAM Delete service type

  • EAM Maintenance job closure

  • EAM Move operations

To use this feature, the following module(s) must be installed according to the terms of your software license agreement:

  • Enterprise Asset Management

You can secure this feature by implementing a range of controls against the affected programs. Although not all these controls are applicable to each feature, they include the following:

  • You restrict operator access to activities within a program using the Operator Maintenance program.
  • You can restrict operator access to the fields within a program (configured using the Operator Maintenance program).
  • You can restrict operator access to functions within a program using passwords (configured using the Password Definition program). When defined, the password must be entered before you can access the function.
  • You can restrict access to the eSignature transactions within a program at operator, group, role or company level (configured using the Electronic Signature Configuration Setup program). Electronic Signatures provide security access, transaction logging and event triggering that gives you greater control over your system changes.
  • You can restrict operator access to programs by assigning them to groups and applying access control against the group (configured using the Operator Groups program).
  • You can restrict operator access to programs by assigning them to roles and applying access control against the role (configured using the Role Management program).

  • The Maintenance warehouse setup option must be enabled against all warehouses that carry stock used for planned maintenance .

Solving

The ledger code that is linked to the equipment code using the Equipment Code Maintenance program is used for the transaction.

If the equipment code is linked to an asset with a capex item, then the ledger code against the capex item is used.

The equipment code must be linked to at least one ledger code when creating a maintenance job.

  1. Launch the Service Structure Maintenance program.

  2. Select the equipment code and maintenance service type for which you want to add a subcontract operation.

    The relating information is displayed in the Maintenance Information pane.

  3. Select Add on the toolbar of the Operations pane.

    The Internal Operation window is displayed by default.

  4. Click on the Operation type field and select Subcontract.

    The window title will change to Subcontract Operation and the fields to add a subcontract operation are displayed.

  5. Enter the required information and click on Save.

  1. Launch the Service Structure Maintenance program.

  2. Select the equipment code and maintenance service type for which you want to add a subcontract operation.

    The relating information is displayed in the Maintenance Information pane.

  3. Select Add on the toolbar of the Operations pane.

    The Internal Operation window is displayed by default.

  4. Enter the required information and click on Save.

Using

  1. Configure the planned maintenance structure:

    1. Define the types of equipment used within the business and the standard service structures for these equipments types using the Equipment Type Maintenance program.

    2. Define the equipment codes to uniquely identify each asset or piece of equipment and link it to a machine, capex project or ledger code using the Equipment Code Maintenance program.

    3. Define the types of services that are required for every equipment type using the Service Type Maintenance program.

    4. Configure the material and operational requirements for every asset and service type using the Service Structure Maintenance program.

  2. Create and share the planned maintenance schedule:

    1. Create the maintenance schedule for each piece of equipment or asset using the Planned Maintenance Job Schedule Query program.

    2. Share the maintenance schedule with engineers and production teams using the EAM List of Scheduled Jobs report.

  3. Review the planned maintenance schedule to prepare for upcoming maintenance tasks using the Planned Maintenance Job Schedule Query program.

  4. Review availability of materials required for the planned maintenance using the Maintenance Job Parts Review program.

  5. Issue material and labor to the planned maintenance job using the Maintenance Job Issues program.

  6. Create maintenance jobs for unplanned breakdowns using the Maintenance Job Entry program.

The following indicates areas in the product that may be affected by implementing this feature:

Program List > Enterprise Asset Management > Setup

This program lets you maintain equipment codes to uniquely identify an asset and specify a ledger code to which the maintenance costs will be posted.

Program List > Enterprise Asset Management > Setup

This program lets you create and maintain equipment types to which equipment codes can be linked. An equipment type can be used to group equipment codes.

Program List > Enterprise Asset Management > Setup

This program lets you maintain services types that are used to identify the type of service or maintenance an asset could require. An asset can have several different service types.

Program List > Enterprise Asset Management > Setup

This program lets you manage operations and components for each service type.

Setup Options > Configuration > Distribution > Inventory> Show Warehouses hyperlink

This program lets you capture and maintain details of warehouses required within the system.

We made the following changes for Planned Maintenance:

  • We added the Maintenance warehouse option against the warehouse that must be enabled for warehouses that carry parts and spares for planned maintenance.

  • The Maintenance field was added to the eSignatures that control the adding, changing and deleting of warehouses.

Program List > Enterprise Asset Management > Transaction Processing

This program lets you create a maintenance schedule per asset or equipment code. The jobs created in this program will always be planned maintenance jobs.

Program List > Enterprise Asset Management > Transaction Processing

This program lets you manually create and maintain jobs for unplanned maintenance.

Program List > Enterprise Asset Management > Setup

This program lets you create and maintain equipment types to which equipment codes can be linked. An equipment type can be used to group equipment codes.

Program List > Enterprise Asset Management > Transaction Processing

This program lets you issue parts and spares to maintenance jobs.

Program List > Enterprise Asset Management > Transaction Processing

This program lets you complete and close a maintenance job.

Program List > Requirements Planning > Requirements Planning

This program lets you review and update existing / suggested jobs that require changes as indicated by the snapshot files. You can change suggested jobs before converting them into live jobs create new jobs from suggested jobs.

The following changes were made to accommodate the Planned Maintenance feature:

  • The Enterprise Asset Management module must be installed to use this program for planned maintenance jobs.

  • On the Review Criteria pane:

    • You can select to include or exclude planned and unplanned maintenance jobs at the Exclude actions section.

    • You can choose to only review maintenance jobs by selecting the Maintenance jobs only option at the Include section.

Accessible from the Add or Change option within the WIP Material Allocations - Browse program.

This program lets you maintain material allocations for a job.

The following changes were made to accommodate the Planned Maintenance feature:

  • The Enterprise Asset Management module must be installed to use this program for planned maintenance jobs.

  • The Copy button or option is disabled for maintenance jobs, as maintenance jobs can't be duplicated.

  • The stock codes used for material allocations must be stocked in a maintenance warehouse.

Program List > Work in Progress > Job Postings

This program lets you post time against a specific job.

The following changes were made to accommodate the Planned Maintenance feature:

  • The Enterprise Asset Management module must be installed to use this program for planned maintenance jobs.

  • The Maintenance information section at the General Information pane lets you select the maintenance job against which you want to post labor.

Program List > Work in Progress

This program lets you maintain the integrity of data in your Work in Progress module. It enables you to close the current month and open up a new month for processing Work in Progress transactions and to delete Work in Progress information that is no longer required in the system.

The following changes were made to accommodate the Planned Maintenance feature:

  • The Enterprise Asset Management module must be installed to use this program for planned maintenance jobs.

  • The Purge maintenance jobs only option at the Function field allows you to delete maintenance jobs.

Program List > Enterprise Asset Management > Reports

Program List > SYSPRO Reporting Services > Enterprise Asset Management

This program lets you generate a list of materials (parts and spares) for equipment codes.

Program List > Enterprise Asset Management > Reports

Program List > SYSPRO Reporting Services > Enterprise Asset Management

This program lets you generate a list of scheduled maintenance schedule per equipment code and job.

Program List > Enterprise Asset Management > Reports

Program List > SYSPRO Reporting Services > Enterprise Asset Management

This program lets you generate a report to view the value of outstanding work in progress for each maintenance job in the last three months.

Program List > Enterprise Asset Management > Reports

Program List > SYSPRO Reporting Services > Enterprise Asset Management

This program lets you generate a report to view the detail of material and labor transactions that have been posted against planned maintenance jobs.

Program List > Enterprise Asset Management > Reports

Program List > SYSPRO Reporting Services > Enterprise Asset Management

This program lets you generate a report that lists the status of each planned maintenance job.

Program List > Enterprise Asset Management > Reports

This program lets you view all parts linked to an equipment code and service type per maintenance job, thereby indicating where gross shortages may occur.

Program List > Enterprise Asset Management

This program lets you view a schedule of planned maintenance jobs in a graphical format.

Program List > Work in Progress

This program lets you view extensive information relating to jobs held on file.

The following changes were made to accommodate the Planned Maintenance feature:

  • The Maintenance job field in the Job Details pane indicates if the job you viewing is a planned maintenance job.

  • The Maintenance information section in the Job Details pane displays information on the equipment, maintenance job and type of service that was carried out.

Accessible from the Capex item field within the Equipment Code Maintenance program.

This program lets you browse for approved capex and lines that are linked to an asset.

Program List > Inventory > Browses

This program lets you view details of your warehouses currently defined.

The Maintenance warehouse column indicates if the warehouse carries stock that is used for planned maintenance.

The following indicates the business objects that are affected by this feature:

The Equipment Code Setup business object lets you add, update or delete an equipment code.

The Service Ledger Codes Setup business object lets you add, update or delete service ledger codes against an equipment code.

The Service Type Setup business object lets you add, update or delete maintenance service types.

The Service Structure Setup business object lets you add, update or delete service structures.

The information you can specify includes the specific revision of the part or spare that will be used to maintain a machine, description of the non-stocked part or spare(s), equipment code and maintenance service type.

The Service Operations Setup business object lets you add, update or delete maintenance structure operations.

The Equipment Type Setup business object lets you configure the setup for equipment types (i.e. used to group equipment codes). The information that you can specify includes the description for an equipment type, associated equipment code and whether a maintenance structure for the equipment code should be used.

The Inventory Warehouse Maintenance business object lets you add, maintain and delete warehouses.

The BOM Tool Set Maintenance business object lets you create and maintain BOM tool sets.

The BOM Specific Narrations business object lets you maintain user defined text that may be defined against jobs, Work in Progress labor allocations, Work in Progress material allocations, BOM structures, BOM operations, estimate structures and estimate operations.

The Maintenance Setup Options business object lets you update the setup options for the Enterprise Asset Management module.

The Planned Maintenance Schedule business object lets you create planned jobs.

The EAM Job Closure business object lets you close maintenance jobs.

The Service Structure Functions business object lets you change the sequence of a component, re-sequence the components, copy a part or spare from another Enterprise Asset Management structure and delete all components.

The Service Operation Functions business object lets you copy, move and delete operations from Enterprise Asset Management structures.

The WIP Job Creation and Maintenance business object lets you add, update or delete jobs.

Jobs can be created for stocked or non-stocked items. When creating a job for a stocked item, the labor and material allocations from the Bill of Materials can be attached to the job or they can be assigned manually. If allocations are being attached to the job, sub jobs can be created for all components in the structure against which it is indicated that a sub job must be raised.

The WIP Job Closure business object lets you set a job to complete and distribute any outstanding work in progress amounts to the ledger.

The WIP Job Receipts business object lets you process receipts against Work in Progress jobs for stocked items.

The WIP Transfer Work in Progress business object lets you transfer the completed quantity from a non-stocked Work in Progress sub job to the attached master job.

The WIP Material Allocations business object lets you add, change or delete material allocations against existing jobs and can be used to maintain both stocked and non-stocked material allocations.

The Maintenance Setup Options Query business object lets you view the maintenance service options for the selected company.

The Schedule Jobs Query business object lets you view the detail of plant maintenance schedules.

The List of Structures Query business object lets you view a list of parts or spares and operations attached to an Enterprise Asset Management structure.

The WIP Detail Report business object facilitates the creation of the WIP Detail report.

The WIP Valuation Query business object facilitates the creation of the WIP Valuation report.

The WIP Job Variance business object facilitates the creation of the Job Variance report.

The WIP Percentage Complete business object facilitates the creation of the Percentage Complete report.

The WIP Job Status Query business object facilitates the creation of the Job Status report.

The WIP Query business object lets you view job header details and extensive information relating to the job.

The Job Actions Report business object facilitates the creation of the Job Actions report.

The WIP Dispatch List business object facilitates the creation of the Dispatch List report.

The BOM Advanced Trial Kitting Query business object lets you generate an XML document containing a trial kit list of components per required date.

The WIP Build Labor Issue business object lets you view labor allocations defined against a job that are used when processing labor postings.

The MRP Demand Utility business object updates the MrpRequirement, MrpDetailPegging and MrpMpsDetPegging tables with existing demand (e.g. forecasts, sales orders, supply chain transfers, material allocations, quotations or store requisitions).

The MRP Supply Utility business object updates the MrpRequirement, MrpDetailPegging and MrpMpsDetPegging tables with existing supply (e.g. supply chain transfers, jobs, purchase orders, requisitions, goods in transit, inventory stock and non-stocked items).