1 Overview to Equipment/Plant Maintenance

This chapter contains these topics:

You can use the maintenance features of the Equipment/Plant Management system to manage all aspects of equipment and machinery maintenance in your organization, such as:

  • Planning

  • Scheduling resources

  • Purchasing parts and materials

  • Tracking the status of preventive and corrective tasks

1.1 System Integration

From Equipment/Plant Management, you can link to other JD Edwards World systems that your organization uses. For example, use the General Accounting system to record maintenance charges against work orders. Use the Work Order Processing system to track and monitor schedules by work order. Other systems that you can link to include:

  • Job Cost

  • Inventory Management

  • Procurement

  • Shop Floor Control

  • Accounts Payable

Because JD Edwards World systems are integrated, you need to enter the vital information about a piece of equipment only one time. When you create equipment masters and supplemental information for a piece of equipment, the system stores the information in the Equipment Master table (F1201). Each JD Edwards World system that you use can then access the information.

System integration also helps ensure that equipment information is consistent throughout your organization. This saves considerable time and money, especially when you need to update or revise equipment information.

This guide describes features and functions that depend on the installation of the complete Equipment/Plant Management system. This system includes the following systems:

  • 05 - Time Accounting (Stand alone Payroll module)

  • 30 - Product Data Management

  • 31 - Shop Floor Control

  • 33 - Resource and Capacity Planning

  • 34 - Material Planning

  • 40 - Inventory Base and Order Processing

  • 41 - Inventory Management

  • 43 - Procurement

Your company might not have purchased all of these systems. Check with your system administrator to verify which systems have been purchased and installed.

The following diagram illustrates the system integration among the Equipment/Plant Management system and other JD Edwards World systems. The accompanying table briefly describes how you use each system within the context of Equipment/Plant Management.

Figure 1-1 Equipment/Plant Management System

Description of Figure 1-1 follows
Description of "Figure 1-1 Equipment/Plant Management System"

The following table briefly describes how other JD Edwards World systems are used within the context of Equipment/Plant Management:

System Description
Address Book Every JD Edwards World system works with the Address Book system to retrieve up-to-date employee, supplier, and other applicable name and address information.
General Accounting When you enter equipment transactions (including billing transactions), you must process them through the general ledger.

You enter all statistical values, such as miles, gallons, and so on, into the general ledger.

When you charge a job for equipment use, the system searches the Account Master for the appropriate rate and account to bill.
Accounts Payable You can enter equipment charges through the Accounts Payable system.

When you process equipment parts orders through the Procurement system, the system automatically enters the equipment number from the purchase order to the accounts payable voucher.
World Writer You use World Writer to create user defined reports, such as additional location tracking and parent and component history reports.
Job Cost When you charge a job for equipment use, the system searches the Job Cost Master for billing rate default values.

When you track equipment location, the job defined in the Job Cost system is often the tracking location.
Payroll and Time Accounting You can use Payroll and Time Accounting to:

  • Enter equipment time for billing purposes.

  • Charge for labor associated with operating or repairing equipment.

  • Charge labor to a work order and a specific labor routing step.
Fixed Assets The Fixed Assets system shares many tables with Equipment/Plant Maintenance, such as the:

  • Item Master table (F1201) - Stores equipment master information

  • Item Balances table (F1202) - Stores equipment account balance information

Equipment/Plant Maintenance also uses automatic accounting instructions from the Fixed Assets system.

You can access JD Edwards World Spreadsheet Tool for Asset Reporting (STAR) through the Fixed Assets system. Use this report writer to create custom reports of equipment balances and units.
Work Orders Use the Work Orders system to track, schedule, and report on preventive and corrective equipment maintenance activities.

You can attach parts lists and detailed instructions (routings) to the work order to assist in planning labor and parts requirements.
Inventory Management Use the Inventory Management system to:

  • Track and take inventory of repair parts

  • Attach parts lists to work orders
Procurement: You can create purchase orders directly from the work order parts list and from other maintenance planning functions within Equipment/Plant Maintenance.

A purchase order includes the equipment number, which the system automatically enters in related forms and tables, such as:

  • Accounts payable entry

  • General ledger

  • Equipment ledger
Manufacturing Systems You can use several programs within JD Edwards World manufacturing systems to plan maintenance parts and labor needs. Use these programs to:

  • Set up the Master Planning Schedule to indicate that machines scheduled for maintenance are not available for use during that time.

  • Project labor and parts needed for maintenance.

  • Generate messages to indicate that parts need to be purchased and resources allocated to perform the needed maintenance.

1.2 Equipment/Plant Maintenance Features

The maintenance features of the JD Edwards World Equipment/Plant Management system are designed to meet equipment maintenance needs in a variety of ways. For example, you can use the system to:

  • Enter and search for equipment information.

  • Track equipment movement and status, and assign equipment to multiple locations.

  • Track the maintenance history of each piece of equipment and target potential problem machines to minimize equipment downtime.

  • Coordinate maintenance activities based on preventive and corrective maintenance schedules.

  • Coordinate maintenance activities with materials and labor resources.

  • Maintain detailed cost accounting records for equipment.

  • Produce reports on a wide range of equipment-related topics.

1.2.1 Equipment Information and Search

You can use Equipment/Plant Maintenance to locate, organize, and track the availability and repair status of equipment using the following types of information:

Information Description
Parent and component relationships A parent is an item or piece of equipment that consists of other parts or components. It can also be a child or component of another piece of equipment.

A parent does not have to represent an actual piece of equipment. You can set up virtual or logical pieces of equipment and establish child relationships with the logical equipment. For example, a manufacturing line could be a parent and the associated manufacturing machinery would be children or components of the manufacturing line.

Use parent and component relationships to group individual components in the system. You can track the history of a piece of equipment's immediate parent or any of its components. The system accommodates up to 25 levels of components. This is useful if you use complex or interchangeable equipment assemblies.
Equipment numbers You can identify equipment by any or all of the following:

  • Unit number

  • Item number

  • Serial number
Supplemental data You can define unlimited types of supplemental data, which you can then assign to any piece of equipment. For example, you might want to track oil consumption, oil analysis, and so on.
Location You can search for and track equipment based on its historical, current, or planned location. This is helpful if you need to review equipment that is used at a particular job site or reroute equipment between job sites.
Category codes You can define up to 23 category codes to classify equipment for reporting and data selection purposes. For example, you can perform online searches for equipment based on category codes that represent major accounting class, major equipment class, manufacturer, model year, and so on.
Other user defined codes You can assign three additional user defined codes:

  • Finance methods

  • Equipment status codes

  • Equipment message types

For example, you can set up equipment status codes to apply to each piece of equipment, such as:

  • Down

  • Standby

  • Working

  • Available
Licenses and certifications You can record and track license and permit information for each piece of equipment. This is helpful if you dispatch equipment to job sites located in different licensing authorities.
Online message logs You can use online message logs to enter messages about a piece of equipment. Standard message types include:

  • Planned maintenance

  • Actual maintenance

  • Problem reports

You can also enter additional remarks about any piece of equipment.

1.2.2 Equipment Location Tracking

You can locate and report on the availability and working status of equipment. You can also:

  • Revise location tracking information.

  • Transfer one or more pieces of equipment.

  • Consolidate equipment from multiple locations.

1.2.3 Detailed Equipment Cost Accounting

Equipment/Plant Maintenance provides you with the following cost accounting features:

Feature Description
Custom chart of accounts You define the chart of accounts for your equipment cost and revenue to meet your unique needs, such as matching a parent company's accounting structure. At any time, you can view these accounts at a summarized or detailed level.
Unit cost analysis You can analyze costs according to the operating hours or miles logged for equipment in payroll, and equipment time entry records or meter reading entries.
Operating and maintenance cost analysis Equipment/Plant Maintenance provides you with various reports on operating and maintenance costs. You can review maintenance costs per mile or per hour or on a monthly, yearly, or acquisition-to-date basis.

1.2.4 Reporting

Equipment/Plant Maintenance provides you with several powerful reporting tools, which offer you a comprehensive view of your equipment needs and processes. These reporting tools include:

Tool Description
Standard reports You can tailor predefined DREAM Writer reports to fit your company's needs and simplify the fulfillment of various IRS reporting requirements. Equipment/Plant Maintenance includes reports, such as:

  • Maintenance Log

  • Maintenance Schedule

  • Location Tracking

  • Work Order Status

  • Work Order Cost Summary

  • Work Order Cost Detail

  • Equipment Cost Analysis
STAR You can design your own equipment reports with STAR. STAR guides you through the setup of custom reports that specifically access the system's equipment and fixed asset files.
World Writer For reporting needs not addressed by standard reports or STAR, you can use JD Edwards World Writer to design and build custom reports, providing unlimited user defined access to your database.

1.3 Equipment/Plant Maintenance Process Flow

The following graphic illustrates the flow of the primary events and processes within Equipment/Plant Maintenance:

Figure 1-2 Equipment/Plant Maintenance Process Flow

Description of Figure 1-2 follows
Description of "Figure 1-2 Equipment/Plant Maintenance Process Flow"

1.4 Equipment/Plant Maintenance Tables

The following information describes the primary and secondary tables within the Equipment/Plant Maintenance system.

1.4.1 Primary Tables and Descriptions

Table Description
Equipment Master (F1201) Stores basic information about each piece of equipment, such as:

  • Equipment number

  • Description

  • Account coding

  • Category codes
Item Balances (F1202) Stores the account balance amount or unit for each equipment account.
Location Tracking (F1204) Stores location information for an equipment item, including:

  • Equipment number

  • Location

  • Start effective date

  • Ending date

  • Equipment status

  • Transfer number

  • Location code, which indicates the type of location, such as planned, current, or history
Maintenance Schedule (F1207) Stores information about each occurrence for a type of service, such as:

  • When the service is to be performed

  • When the service was last completed

  • Current status

  • References to any associated work order
Work Order Master (F4801) Stores static information about each work order, such as:

  • Description of work

  • Budgeted amount and hours

  • Equipment worked on

  • Charging information
Account Ledger (F0911) Stores General Ledger journal entry audit trails for both the Item Balances table (F1202) and the Account Balances table (F0902).

1.4.2 Secondary Tables and Descriptions

Table Description
Supplemental Data (F12090, F12092, and F12093) Stores additional information about equipment in either columnar or narrative format.
Supplemental Data Cross Reference (F1392) Stores valid supplemental data types for classes of equipment that are defined by category codes.
Specification Data Table (F1216) Stores static equipment information, such as power requirements, size, capacity, and other nameplate information.
Item Messages Log (F1205) Stores messages regarding equipment maintenance.
License Master (F1206) Stores license and permit information for equipment.
Model Maintenance Schedule (F12071) Stores model maintenance schedules.
Location History Text (F1210) Contains text for location history records.
Parent History (F1212) Contains the history of parents for a component.
Specification Cross Reference Table (F1215) Stores the valid values for each field in the Specification Data Table by class of equipment.
Meter Reading Estimates (F1306) Maintains estimated meter readings.
Status History (F1307) Maintains a history of status changes to equipment and work orders.
Maintenance Loops (F1308) Stores equipment maintenance information by associated equipment and service type.
Equipment Category Code Mapping (F1391) Maintains the rules by which the system automatically assigns equipment and business unit category codes when you create master records for new equipment or create work orders for equipment.
Maintenance Rules (F1393) Defines when preventive maintenance will be scheduled and provides default values to work orders.
PM Projections (F13411) Maintains information about projected PMs by service type for each piece of equipment.
Work Order Record Types (F48002) Stores text associated with work orders.
Work Order Parts (F3111) Maintains information about parts related to specific work orders.
Work Order Routing (F3112) Maintains information about the labor steps related to specific work orders.
Work Order Instructions (F4802) Stores description text and the various record types that are defined in the user defined codes, such as Description of Request and Final Disposition.
Work Order Status Action (F4826) Maintains information about the order of allowed statuses through which a work order must pass.
Work Order Approval Routing (F4827) Maintains information about work order approvers.
Work Order Approval (F4828) Stores audit information for work order approvals.
Bill of Material Master (F3002) Stores information about the parts needed to perform a specific type of maintenance.
Routing Master (F3003) Stores detailed instructions by labor step for a specific type of maintenance.
Forecast (F3460) Stores the forecast data that the Material Requirements Planning (MRP) program uses for calculations.
Default Accounting Constants (F12002) Maintains default account information by company and asset cost account.
Default Depreciation Constants (F12003) Maintains default information by company and asset cost account of all depreciation books and values.
User Defined Codes (F0005) Contains all user defined system values.
Address Book Master (F0101) Contains tax assessor and equipment user address information.
Account Master (F0901) Maintains general ledger account data.
Automatic Accounting Instructions Master (F0012) Contains information used to define the interfaces between Equipment/Plant Maintenance and the General Accounting chart of accounts.

1.5 Equipment/Plant Maintenance Menu Overview

JD Edwards World systems are menu driven. System functions are organized according to their frequency of use. Access Equipment/Plant Maintenance menus from the Equipment/Plant Management menu (G13).

Figure 1-3 Equipment/Plant Maintenance Menu Overview

Description of Figure 1-3 follows
Description of "Figure 1-3 Equipment/Plant Maintenance Menu Overview"