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Chapter – 7 Maintenance Management Module The primary purpose of this module is to record the different maintenance activities performed on a machine and thereby generate information on the performance of a machine. Other related actvities like recording the usage of spares in different sections and tracking the movement of spares from one section to another may also be done. When maintenance work is required on a machine, a person from the particular section where the machine is installed has to enter the machine handover details. On entering the machine number, the computer cross checks the validity of the machine number and the machine description and section are automatically displayed. The type of maintenance (electrical, electronic, mechanical etc) involved must be entered. Maintenance transactions are to be registered for breakdown as well as preventive maintenance. Once the machine has been handed over for maintenace, the maintenance section should register the planned date of completion of the maintenance activity. When the maintenance work is over, the restoration details are to be recorded. The number of persons involved in each grade and the number of hours worked has to be entered for each grade of labour involved in the maintenance activity. The labour cost is calculated and recorded. Once the preventive maintenance activities on each machine have been identified,the preventive maintenace schedule should be planned for a given period. The period for which the preventive maintenance activities have been planned should be entered. Then for each machine scheduled date of the preventive maintenance should be entered. The scheduled date should not exceed the plan period. This actvity needs to be done after every plan period. The different preventive maintenance activities that are to be done on each machine are identified and registered. The interval after which the activity needs to be done again and the expected duration in hours is to be entered. Once a preventive maintenance has been done on a machine, the date when the same activity is to be done again is to be recorded. The available stock of spares in a section must be initialized. Whenever a certain quantity of a spare is required in a section, it may either be drawn from the main stores against a demand note or it may be obtained from another section where it is available. The sectional stock of that spare is then updated. Whenever a spare is transferred from one section to another, the transfer details must be recorded. The quantity is then reduced from the sending section whilst the quantity of that spare is increased in the receiving section. The quantity of spare material used in a maintenance activity must be recorded before the machine is restored back in the section. The material cost is calculated and recorded by the system. This may be used to generate the total maintenance cost for a particular machine. Ordnance Factories Institute of Learning, Dehradun 77
Machine utilisation is to be recorded at the end of every month. The actual number of shifts worked by the machine in that month is to be entered. In case of machines for which the actual number of shifts is not available, the computer generates the machine utilisation taking into consideration the normal number of shifts in the section and the total number of shifts idle due to maintenance. The number of shifts worked in a month obtained after executing the machine utilisation option, is converted into hours with the help of a standard conversion factor. The monthly depreciation of the machine may be generated after the machine utilisation has been registered. The monthly depreciated value is recorded. The book value may be calculated for new machines. main - mm000nmain CONTENTS 1. Maintenance Transactions - mm100nmenu 1. Machine Breakdown - mm100ahdor 2. Machine PDC - mm101ppdc 3. Machine Restoration - mm100placm 2. Preventive Maintenance - mm200nmenu 1. Add Planned PM schedule date - mm200aplpm 2. Add PM activity - mm200apmdt 3. Update scheduled PM date - mm200apmsc 3. Spares Management - mm300nmenu 1. Initialize opening balance of stock - mm300aspre 2. Recording intersection transfer of spares - mm300asptr 3. Update usage of spares - mm300aspug 4. Machine Utilisation and Depreciation - mm400nmenu 1. Add monthly machine utilisation - mm400umutl 2. Machine hours updation - mm400umhrs 3. Machine depreciation calculation - mm400udepc 4. Book value calculation for new machines - mm400ubkvl 5. Reports - mm600rpmen 1. Daily Breakdown Report - mm600bkd 2. Weekly Breakdown Report - mm600bkw 3. Preventive Maintenance Chart - mm600pmchk 4. Preventive Maintenance Report - mm600bkw 5. Machine Utilisation Report 6. Depreciation For Idle Machines 7. Report On Periodic Maintenance Cost - mm600mnt 8. Depreciation For Machines 9. Machine History - mm600hist Ordnance Factories Institute of Learning, Dehradun 78
Page 1 and 2:
INDEX Chapter Topic Page No. 01. Op
Page 3 and 4:
the dedicated keys. b) Depending on
Page 5 and 6:
Module names and their respective d
Page 7 and 8:
specification of the material more
Page 9 and 10:
CONTENTS main - im000menus 1. RR/LW
Page 11 and 12:
21. Loss statement for every DD vou
Page 13 and 14:
CONTENTS main - po000menu 1. Purcha
Page 15 and 16:
11. Vendor Item Add - po132vitm Mod
Page 17 and 18:
data available in the computer, tha
Page 19 and 20:
3. Net requirement calculations (mp
Page 21 and 22:
Chapter - 4 Vendor Analysis The pri
Page 23 and 24:
the payment is to be a part (provis
Page 25 and 26:
6. Statement of payment - pa105r007
Page 27 and 28: 3. Warrant WIP Calculation (ct003nw
Page 29 and 30: 5. Trransfer voucher abstract (ct00
Page 31 and 32: Chapter - 6 User Manual on Database
Page 33 and 34: 11. Manufactured item master Add -
Page 35 and 36: Option: Modify a party record in pa
Page 37 and 38: Option: Suspend a party db010party
Page 39 and 40: Input: Machine number Second input:
Page 41 and 42: db022machn MACHINE MAINTENANCE RECO
Page 43 and 44: db030mcspr MACHINE SPARES MASTER DB
Page 45 and 46: db040tools TOOLS MASTER DB004TOOLS
Page 47 and 48: EP code :[ ] Drawing number :[ ] Es
Page 49 and 50: Option: Query on standard man hour
Page 51 and 52: db060estmt MATERIAL ESTIMATE MAINTE
Page 53 and 54: [f002 ][a ] [b ] [f004 ] [f005 ][f0
Page 55 and 56: Sl. Order No [ ] Order Type [ ] ORD
Page 57 and 58: db091order ORDERS MASTER DB009ORDER
Page 59 and 60: Option: Print a list giving the req
Page 61 and 62: db111stitm STOCK ITEM MASTER Screen
Page 63 and 64: the computer. If the specifications
Page 65 and 66: Inspection responsibility [ ] Packi
Page 67 and 68: db121mfitm MANUFACTURING ITEM MASTE
Page 69 and 70: Description :[ ] Godown keeper: [ ]
Page 71 and 72: description Action: The set of valu
Page 73 and 74: ___________________________________
Page 75 and 76: itm_cd char(10) Item code est_sl sm
Page 77: ev_no smallint rat_fm_no char(10) R
Page 81 and 82: Option: Machine breakdown mm100ahdo
Page 83 and 84: Option: Preventive Maintenance mm20
Page 85 and 86: mm300nmenu MM300NMENU SPARES MANAGE
Page 87 and 88: Option: Machine utilisation and dep
Page 89 and 90: utilisation has been added and whic
Page 91 and 92: Chapter - 9 Tools Control Activity
Page 93 and 94: A) Tool transfer This option record
Page 95 and 96: Chapter - 10 Work in Progress MAIN:
Page 97 and 98: (wi100r010.4gl, wi100rmen.4gl) 1. D
Page 99 and 100: d. Warrant issue date e. Planned da
Page 101 and 102: Data expected: a. Work order number
Page 103 and 104: Action: Input: Extract Number, Work
Page 105 and 106: Action: Operation Code, Authorized
Page 107 and 108: [ ] [ ] [ ] [ ] [ ] [ ] Input: Work
Page 109 and 110: With the above data material is tra
Page 111 and 112: Item Code : [ ] [ ] Warrant Quantit
Page 113 and 114: material or labour has been drawn i
Page 115 and 116: 5. CONSTRAINTS MAINTENANCE (ds006nc
Page 117 and 118: time_batch = set_tm + proc_tm where
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