Understanding Condition-based Maintenance

Oracle's PeopleSoft Maintenance Management condition-based maintenance (CBM) enables you to make maintenance decisions based on the actual condition of the asset. You can identify equipment problems early, when they are less costly to correct, and perform maintenance only when needed.

Condition-based maintenance in PeopleSoft Maintenance Management:

  • Requires the setup of Web Services and Integration Broker to enable communication to external monitoring systems, as well as the setup of PeopleSoft workflow and condition-based maintenance rules for PeopleSoft Maintenance Management.

  • Uses alerts generated from real-time equipment monitoring devices that assess equipment conditions against predefined, normal operation parameters.

  • Provides real-time alerts when equipment is operating outside of normal bounds so appropriate maintenance action can be taken.

  • Initiates appropriate maintenance action, including creation of a work order, and PM schedule updates.

External systems measure and analyze current equipment readings and determine whether the condition of the equipment is outside of normal operating parameters. When the condition is outside normal operating parameters, an alert triggers a response and follow-up action. Users can manually create an alert or an external software program can create an alert.

Then, depending on the setup rules, the system sends a message to the CBM coordinator by email or through a worklist indicating the condition exists. The CBM coordinator reviews the alert and can either create a work order, or, if the alert can be handled using a preventive maintenance work order, the coordinator updates the PM schedule, which is used by the Preventive Maintenance process to generate a work order. The system tracks the status of an alert throughout its life cycle.

The following terms are included in these topics:

Field or Control

Definition

Web Service

Web service as a software service exposed on the Web through SOAP, described with a WSDL file and registered in UDDI. Web services are the fundamental building blocks in the move to distributed computing on the Internet.

SOAP

As the communications protocol for Web services, SOAP is a lightweight protocol intended for exchanging structured information in a decentralized, distributed environment. SOAP uses XML technologies to define an extensible messaging framework, which provides a message construct that can be exchanged over a variety of underlying protocols. The framework has been designed to be independent of any particular programming model and other implementation specific semantics.

WSDL

WSDL (often pronounced whiz-dull) stands for Web Services Description Language. A WSDL file is an XML document that describes a set of SOAP messages and how the messages are exchanged. WSDL is an XML format for describing network services as a set of endpoints operating on messages containing either document-oriented or procedure-oriented information. The operations and messages are described abstractly, and then bound to a concrete network protocol and message format to define an endpoint. Related concrete endpoints are combined into abstract endpoints (services).

There are specific steps that you must perform to enable condition-based maintenance in PeopleSoft Maintenance Management.

  • To create alerts using Web Services, set up:

    • The external system that is used for monitoring the asset must follow Web Service standards and publish WSDL.

    • Web Services to work with PeopleSoft Integration Broker, which enables component interfaces and messages to be offered to third parties as web services.

  • To create both Web Services and manual alerts, you must assign the role and route control profiles to the CBM coordinator's user profile.

    The role of CBM Coordinator (WM_CBM_COORDINATOR) and the Route Control Profile (WM_CBM_US001) have already been set up in the system data.

    PeopleSoft Workflow sends a notification message. In the worklist and email, use the "Two Route Controls Qry" from the recipient in the Fields Mapping. The role WM_CBM_COORDINATOR is passed as a bind variable for ROLENAME. Business unit and shop ID are passed as the other two bind variables.

  • In PeopleSoft Maintenance Management, set up condition-based maintenance rules.

The system uses the rules you set up on the Condition-Based Maintenance Setup page to route alerts to the correct work order business unit and shop and thus the appropriate CBM coordinator. These rules also indicate maintenance type, work order type, and service group default values that will display in the work order or the PM schedule depending on the selected rule. The rules are selected by weighting each of the characteristics They provide default values for these actions:

  • Update a PM schedule and run the Preventive Maintenance Process to generate a work order.

  • Create a work order manually.

Important! You must set up a user in PeopleSoft Security for the CBM Coordinator role.

The condition-based rules assign a weight to each of the attributes of an asset. The system matches the attributes of the asset associated with the alert with these rules and assigns the with rule with the highest total weight. The asset attributes and their associated weights are:

  • Asset Type: weight = 1

  • Asset Subtype: weight = 2

  • Asset Location: weight = 4

  • Asset Area: weight = 8

  • Asset ID: weight = 16

You can also enter a wildcard for the above attributes, which is equal to zero (0).

Note: You can assign any values you want to each attribute, if desired.

For example, if an external system is monitoring the condition of a building's air conditioning system where each unit has a monitoring attached to it that measures electrical load produced by the air conditioner. If the monitor on Unit A indicates that the electrical load has increased out of normal range, the system issues a message that the unit needs repair. Unit A is identified as: Asset Type: Facility; Asset Subtype: HVAC/Heating

  • Asset Type: Facility

  • Asset Subtype: HVAC/Heating

  • Asset Location: US001

  • Asset Area: Building B

  • Asset ID: BAC000000A1

The condition-based rules that are set up in your system include (both tables apply to the same 5 rules):

Row#

Asset Type (wt = 1)

Asset Subtype (wt =2)

Asset Location (wt =4)

Asset Area (wt =8)

Asset ID (wt =16)

Total Row Weight

1

%

0

%

0

%

0

%

0

%

0

0

2

IT Hardware

1

SERVER

2

%

0

%

0

%

0

3

3

IT Hardware

1

Laptop

2

US001

4

%

0

%

0

7

4

Facility

1

HVAC/Heating

2

US001

4

%

0

%

0

7

5

Facility

1

HVAC/Heating

2

%

0

%

0

%

0

3

Row #

Business Unit

Shop

Maintenance Type

WO Type

Service Group

1

US001

Shop A

MINOR

CM

MAINT

2

US001

Shop B

MAJOR

PM

MAINT

3

US001

Shop B

MINOR

PM

MAINT

4

US002

Shop A

MINOR

CM

MAINT

5

US002

Shop C

MINOR

PM

MAINT

Based on the asset attributes you selected and the rules, the system matches:

Asset Attribute

Selected Asset Attributes

Matching Rule

Asset Type

Facility

Row 4 - Facility

Row 5 - Facility

Asset Subtype

HVAC/Heating

Row 4 - HVAC/Heating

Row 5 - HVAC/Heating

Location

US001

Row 4 - US001

Row 5 - %

Asset Area

Building B

Row 4 - %

Row 5 - %

Asset ID

BAC000000A1

Row 4 - %

Row 5 - %

RESULT: The system selects Row 4 because the total weighting for Row 4 = 7 and the total weighting for Row 5 = 3. Since row 4 is higher, the system will default the values work order business unit (US001), shop (Shop A), maintenance type (Minor), work type (CM), and service group (MAINT).

Note: Row 1 is also matched because the weight = 0. It is wise to include this general rule to enable the system to catch all of the alerts should no specific rule exist.

Each alert has a system-generated ID. During setup you specify the last CBM alert ID number used. The system uses this number to generate sequential Alert IDs for the Asset Management Business Unit alerts.

See documentation PeopleTools: Integration Broker

An external condition monitoring system sends a SOAP (Simple Object Access Protocol). request to PeopleSoft Maintenance Management when it detects an asset that is out of operational limits. Condition-based Maintenance receives the message of an alert via Web Services working with PeopleSoft Integration Broker.

When the system receives an alert from an external condition monitoring system it takes the following steps:

  1. Receives the SOAP request message of a new alert.

  2. Validates the SOAP request message.

  3. Uses the matching rules to populate the work order Business Unit and Shop ID.

  4. Generates the Alert Identification.

  5. Triggers the workflow to notify the person with the CBM Coordinator role and matching profile.

  6. Saves the alert.

  7. Sends back Alert Identification in a SOAP response message.

If the system finds an error in the request it sends back an error message to the external condition monitoring system. If the system cannot find a matching rule or a CBM Coordinator role user, it sets the status of the alert to Error when the alert is saved.

See documentation PeopleTools: Integration Broker

To enter an alert manually:

  • A user determines that an asset performing outside operational limits.

  • The user creates an alert on the Condition-based Maintenance Alert page.

  • System matches the input to the Condition-based Maintenance Rules and populates the work order business unit and shop ID fields in the alert.

  • The system generates an Alert Identification.

  • Alert triggers workflow to notify the CBM Coordinator.

  • Save the alert, which updates the Alert Status History.

After receiving an alert the CBM Coordinator can create a work order, or update the PM schedule and the Preventive Maintenance process generates a work order. When the CBM coordinator clicks the Create Work Order button the system retrieves the default values and displays them on the Create Work Order page based on the matching rule. The CBM Coordinator can change the values if desired. The system creates the work order when the CBM Coordinator submits the request by clicking the OK button. You must access the work order component to create tasks and assign and schedule resources. If you plan to schedule a crew for this work order, you must use the Crew Scheduling Workbench and the Labor Assignment Workbench as well. The system updates the alert status to Work Order Created. When a work order is closed or cancelled the system updates the status of the related alert to close.

If the CBM Coordinator clicks the Update PM Schedule button, the Update PM Schedule page contains the default values based on the rules. The system updates the PM schedule, which was set up for this asset, and displays the schedule ID on the Condition-Based Maintenance Alert page. The system also updates the CBM Alert tab of the Preventive Maintenance Schedule Workbench for the PM schedule, indicating the source of the alert and if the override option is turned on in the schedule to enable the Preventive Maintenance process to generate a work order.

Understanding Preventive Maintenance Work Orders