Control - Maintenance Systems

The Managing Director of Zero Carbon Engineering was involved in setting up maintenance systems both in FMCG internationally and in retail in the UK. He has worked with SAP PM, Maximo, Shire Systems and Verisae.  His learning has been that they should all be configured at the highest level in the same way.

At the core of the system is the asset register, with every piece of equipment described and identified by its manufacturers serial number.  Each asset is then given a location - for larger companies by country, site, area and then location. Any maintenance history is then assigned to the asset (individual serial number) so if it moves we track one item failing in multiple places - rather than thinking we have single failures of multiple pieces of equipment. 

The planned maintenance plan is linked to the asset and this creates scheduled maintenace tasks. 

Some of these may be purely inspections (e.g. measure wear) but may drive a task as a reaction to the scheduled maintenance task (e.g. wear is excessive so replace item. The secondary tasks are captured as reactive tasks. 

Finally plant may break down. Any repairs to failed plant are captured as malfunction tasks. 

Spare parts are linked to the multiple assets they are used on. Any parts drawn from stores are captured as part of the work order and assigned to the asset. 

The stores process behind this defines the store holding strategy for each part, where it is stores and the procurement strategy (e.g. when stock drops to X then buy more to return stock to Y. 

Finally the system tracks maintenance costs as parts, services and labour and also tracks each assets values and its depreciation.