MAXIMO 6.0 Student Manual
MAXIMO 6.0 Student Manual
MAXIMO 6.0 Student Manual
Version 6
Version 6
Table of Contents
CHAPTER 1: Introduction
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CHAPTER 3: Locations
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CHAPTER 6: Assets
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Chapter 1: Introduction
Chapter 1: Introduction
MAXIMO is Strategic Asset Management (SAM) software that manages all strategic
asset to increase utilization and reduce operation cost so that the profit of the company is
increased as well.
1. Strategic Asset:
Strategic assets are those assets that are directly or closely associated with revenue
generation or that are critical to the mission of the organization. They include the
following types of assets:
Tangible
Fixed
Physical
Capital
2. What Is SAM?
capital assets that have a direct and significant impact on achieving corporate objectives.
investment.
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Chapter 1: Introduction
3. Four SAM Categories:
SAM is focused on four broad categories of fixed, physical, and capital assets:
Production, Facilities, Fleet, and IT.
Asset Categories:
Description
Asset
Category
Production
Facilities
Fleet
Fleet assets are often over-the-road vehicles such as cars and trucks; however, this
category also includes airborne fleets (aircraft), rolling stock (rail cars), and marine
assets (passenger boats and ships). Companies might have mission- critical fleet
assets around which the core of their business is built; for example, a commercial
shipping company depends on its trucks and aircraft. Vehicles for a public transit
organization like Long Island Railroad also fall into this first category.
Additionally, companies might have enterprise fleet assets that are important to the
overall function of an operation but do not directly generate revenue, such as
employee shuttle buses, repair trucks, or forklifts.
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Chapter 1: Introduction
4. Why SAM?
With pressure mounting to improve financial performance in the face of a difficult
economic climate, companies are looking in all directions to increase revenue, reduce
costs, and mitigate risks. SAM is a more sophisticated and comprehensive approach to
extracting greater lifetime value from asset investment; it is one relatively unexplored
avenue that offers an opportunity for significant gains.
Commercial returnMaximize the value that the assets add to the business.
Strategic valueOptimize the market value and flexibility of the asset base.
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Chapter 1: Introduction
8. World-Class Benchmarks:
Some world-class benchmarks and performance goals are: .
Maintenance costs
Planned maintenance
Maintenance overtime
Maintenance rework
Inventory turns
Training
Safety
The financial value lost due to breakdowns (whether by lost production, lost
I can illustrate the importance of this by giving a catastrophic example. If you only had
two breakdowns in the last three years, but ifbecause of these breakdownsyour plant
is on the verge of being closedthen you should be examining your PM program, even
though you "only had two breakdowns in three years."
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Chapter 1: Introduction
Simply noting that the breakdowns are taking place is not likely to provide the
information needed to prevent them. However, noting both the breakdowns and their
consequences might provide the information you need to decide whether you need to
conduct a more detailed review."
Dana Netheron, Jan. 2003 - Plant Maintenance Web site
STEP 5
Creating Organization
and Sites
(CH 2)
STEP 2
STEP 6
Creating Locations
(CH 3)
Job Plans
(CH 7)
STEP 3
STEP 7
STEP 4
Setting Up Inventory
Items (Spare Parts)
(CH 5)
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Chapter 1: Introduction
11. All Modules (applications) in MAXIMO are working together (Maintenance Activity):
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Chapter 1: Introduction
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Chapter 1: Introduction
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Chapter 1: Introduction
c. Maximo Applications:
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Example 2:
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Chapter 3: Locations
Chapter 3: Locations
1. Introduction
One of the principal benefits to using Maximo is the ability to track maintenance costs
against your various assets and operating locations. To track and monitor work and costs
by location, you first need to create the location where the asset is to be located and
based. A location is used to define where an asset physically is and what it is doing.
Work orders can be written against a location only where the asset operates.
2. Learning Objectives
When you have completed this chapter, you should be able to:
3. Implementation
Identify high-priority operating locations and enter them first. Low- ^
priority
Creating and using location hierarchies lets you track work and costs individually,
Creating location hierarchies and systems will enable users to easily find
documentation should be graphically laid out well for your location hierarchy. This
documentation can act as a map as you identify and enter locations and systems into
Maximo.
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Chapter 3: Locations
Location and system hierarchies should be an integral piece of a site implementation;
they are the backbone of the system. A well-thought-out hierarchical design makes it
easier to track assets and costs as related to locations.
In addition, the time and thought you invest in planning the locations and systems creates
a more strategic approach in navigating the Assets/Locations
continued on next page
menus.
Locations are like addresses; for example, if you live at 5 Green Way Plaza, you may
start out in a tent, then a trailer, then a building. So, even though the structure you are in
changes, the address remains 5 Green Way Plaza. If you apply the same logic to locations
and assets, locations normally do not change; however, the assets that reside at the
location might change.
Location hierarchies let you group assets and locations into areas of responsibilities. A
location hierarchy can be designed to include all location. in your plant against which
work orders are written, and can track the movement of assets into and out of locations.
Maximo identifies location hierarchies as systems.
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Chapter 3: Locations
Location networks can have multiple parents and have no defined branching
relationships.
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Chapter 3: Locations
The Locations application lets you enter and maintain operating location w assets and
organize these locations into a logical hierarchy. The Location application screen
contains multiple pages designated by tabs, and is access^ from the Assets module in the
Start Center.
Menu
Function
List
Location
Assets
History
Display the history of the asset's movement transactions into and out of the
location.
Safety
View, add, or delete safety records associated with the selected location.
Meters
Specifications
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Chapter 3: Locations
6. Location Type:
Location Type
Description
Courier
Used to track assets that a courier is holding until they are received into
another location.
Holding
Labor
Associated as location records so that you can track assets and inventory
issued to specific individuals, such as:
Expensive tools
Safety gear
Operating
Repair
Used to track assets when they have been removed from an operating
location for repair.
Salvage
Vendor
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Chapter 3: Locations
7. Drill Down Menu from Select Action:
The function of drill down menu is to show the hierarchy tree of the available locations.
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Chapter 3: Locations
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2. Definitions
The following terms are used in Maximo to manage person records:
People - In Maximo, you use the People application to contain person records of
all people associated with Maximo as users or labor or groups who might be involved in
other ways, such as part of a work or owner group.
transactions in any of the work-related Maximo applications, such as work orders. Labor
is identified by labor codes.
Person groups - These consist of two or more persons who can be designated as a
single entity on work orders as a work group or owner group, or on tickets as an owner
group. The individuals in the group might or might not be users or labor.
Labor and Users Are Persons
Users - A Maximo user is anyone who signs in to Maximo. Some people might
only view information in Maximo, but they are still users. Users are identified by user
names.
Note: All labor and Maximo users must be associated with a person record.
Person records are maintained using the People application in the Resources
module.
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Labor personnel
Users of Maximo
Custodians of assets
Vendor contacts
Metric Description
What percentage of all hours worked is overtime
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This functionality allows work orders and other types of records to call for more
specific skills.
The right craft could be requested for the job, and the appropriate pay rate would
With the ability to ask for specific levels of crafts, you can avoid having the
master electrician show up to do a simple job, thus more accurately controlling costs.
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Outside Rates
Premium Pay
Description
Defines the skill levels available for this craft,
along with associated costs.
Note: The Skill Level Rank field is especially
important because it allows the Assignment
Manager application to choose skill levels at the
desired rank and higher when finding labor for
work.
Describes the outside vendors who might also
provide labor for this craft. It shows the vendors,
craft levels, and contract numbers, where
applicable.
Shows the premium pay categories available for
this craft. Existing premium categories can be
added by clicking New Row. New categories can
be added by choosing Manage Premium Pay
Codes from the Select Action menu, then adding
the new code to the craft record.
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describe the item kits and condition codes functions of the inventory applications
Rotating assets
Alternate items
Definition
The basic non-serialized unit for things/parts that are
kept in inventory.
A record for an inventory item that does not include
the location.
A record for an item at a storeroom location.
An inventory item, with a generic item number and a
current balance (which can be greater than one),
multiple instances of which can be used in multiple
locations.
An individual instance of a rotating item, identified
by an individual asset number.
Items/parts that can be used interchangeably with
other inventory items.
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Metric Description
% Non-critical spares as a % of
total inventory value
% Non-critical spares as a % of
total inventory value
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3. Item Set:
Maximo
There are three categories of inventory items in Maximo: stocked, non- Stocked,
andstocked, and special order items.
Category
Description
Stocked Items
Items that you always need to have on hand because they have
a regular turnover rate and are frequently needed. Stocked items
have reorder criteria specific to each storeroom location.
Non-stocked Items
New
Used
Rebuilt
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To...
List
Inventory
Reorder Details
Rotating Assets
Where Used
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6. Reordering:
Setting up and using reorder in Maximo reduces "stock outs" and also allows for
improved purchase planning. Organizations can realize a 5% to 10% or higher reduction
in inventory levels.
Example:
Satellite stores reordering from the Primary - hub storeroom will allow you to consolidate
purchasing.
Depending on your business and how you keep inventory, you can use the Maximo
reorder routine regularly to reorder inventory items. In Maximo, there are two actions
that allow you to reorder items:
Reorder Items
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Chapter 6: Assets
Chapter 6: Assets
1. Term:
1. Non-Rotating Asset.
Assets for which you want to keep a repair history, but that will not be stored in
inventory.
2. Rotating Item/Rotating Asset.
Assets that are interchangeable, such as motors, pumps, fire extinguishers, or PC
monitors. Rotating assets have both a unique asset number and an inventory item number.
The item number lets you track assets as a group as they are moved into and out of
inventory and other types of locations. Each piece will have the same item number and a
different asset number.
For example, a company might have five similar centrifugal pumps in that all five are the
same make and model. Therefore, they all have the same item number. However, each
pump is a unique unit of asset with its own history of use and repair. Therefore, each
pump has its own unique asset number, which enables you to track maintenance and
related costs.
3. Items.
Generic identifications of assets or spare parts. IT establishes the attributes of the rotating
asset (asset) associated with it.
4. Locations.
Functional identifications where assets can reside.
Metric Description
% Total downtime
% Maintenance downtime
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% Planned/Scheduled downtime
% Unscheduled downtime
mechanical
% of breakdowns preventable
% Asset uptime
Asset availability
Description
Summarizes the failures, by problem code, for an asset
between the specified dates. Links are available to view these
failures graphically. Problem codes are linked to the Drilldown
into Asset's Failures report.
Displays problem causes and remedies for the selected problem
code.
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Chapter 6: Assets
Asset Cost Rollup
2. Non-Rotating Asset
Start its lifecycle at a location. Non-rotating assets do not move into and out of
storerooms and are not tracked in inventory.
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Chapter 6: Assets
5. Non-Rotating asset scheme:
The Assets application enables you to keep and update the records of all of your assets
and operating locations. Use the Assets application to add new assets to the database and
define relationships among these assets.
Asset Screen:
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Chapter 6: Assets
6. Asset Status:
The Status field is used to indicate when an asset is:
Not Ready - Default status for new asset records. Asset records can be created
before assets have been received, installed, configured, inspected, or otherwise approved
for their intended use.
Decommissioned - Asset has been retired from service and moved to scrap or
salvage.
Use the Item Assembly Structure application to build and apply spare parts to an
asset or to an item. You can also apply an IAS at the time of receiving an asset or item.
On the Assets application's Spare Parts tab, associate those items as spare parts to
In the Item Master application, select the Add Spare Parts option to indicate that
the item will be added as a spare part for the assets when issued, if the item is not already
a spare part.
8. Asset Type:
Description
Asset
Category
Production
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Chapter 6: Assets
Facilities
Fleet
Fleet assets are often over-the-road vehicles such as cars and trucks; however, this
category also includes airborne fleets (aircraft), rolling stock (rail cars), and marine
assets (passenger boats and ships). Companies might have mission- critical fleet
assets around which the core of their business is built; for example, a commercial
shipping company depends on its trucks and aircraft. Vehicles for a public transit
organization like Long Island Railroad also fall into this first category.
Additionally, companies might have enterprise fleet assets that are important to the
overall function of an operation but do not directly generate revenue, such as
employee shuttle buses, repair trucks, or forklifts.
IT
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Metric Description j
Percentage of work orders that were j
planned.
% Planned/Scheduled downtime
Unplanned %
% of Work Orders with Work plans Percentage of work orders with work orders
independent of a job plan being associated to
independent of Job Plans
it.
A job plan is the heart of a proactive maintenance program. It represents the accumulated
knowledge of the manufacturer, skilled mechanic, and engineer. It indicates what to do,
what to use, what to look for, how to do it, arid when to do it.
In Maximo, job plans are used as templates for work orders that have been associated to a
record in the Preventive Maintenance, Condition Monitoring, and Routes applications, or
associated to a work order in a Waiting for Approval (WAPPR) status.
Use job plans to:
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estimate the operations, materials, labor, and tools required for maintenance tasks
establish a template for maintenance work that is repetitive (e.g., major overhaul,
A work plan describes the labor, materials, tools, and tasks needed to complete a specific
work order. The work order contains tasks for each operation in the work plan. When you
generate a work order, Maximo copies an associated job plan to the work order as a work
plan. This allows you the flexibility to modify tasks in a work plan without modifying the
original job plan; these changes do not affect the original job plan.
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Preventive maintenance,
Corrective maintenance.
Before work orders can be associated with an asset, the status of the asset must be
Operating.
Using the Condition Monitoring application, where PMs are generated when
the assets' acceptable upper and lower limit meter readings are reached.
Introduction
PM frequencies are based on defined meter units used since the last work order was
completed or targeted to start.
2. Meter Types
Three types of meters can be created:
accumulation.
Example: Miles, flight hours
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Metric Title
Metric Description
% Work orders completed within 20% What percentage of work orders were
of estimated labor
completed within plus or minus 20% of the
labor estimate.
% Work orders completed within 20% What percentage of work orders were
completed within plus or minus 20% of the
of estimated material $
material estimate.
% Work orders waiting on parts
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Preventive (PM): is scheduled work (fully planned) that is based on either time or
meter.
Event (EV): is an unscheduled event that stops work (production) but does not
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Description
Status
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Metric Description
% PM inspections overdue
% PM inspections completed
Metric Title
Metric Description
% PM inspections overdue
% PM inspections completed
Time-based PMs are based on elapsed time since previous work. For example,
every 6 months.
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Meter-based PMs are based on meter readings off an asset record. For example,
Combination-based PMs are based on time and meter readings. For example,
8.2 Master PM
Benefits of
Though master PMs cannot generate work orders, using the master
PM Using Master
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Note: Go to menu list all applications that MAXIMO has. In each application, there are
modules that we can use.
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And
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Note: for all MAXIMO field, the fields that are in Grey mean that we can not
enter any value (the value is fixed by the system/filled up automatically by the
system).
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5. Set the parent (if it has) by clicking the new row in parent
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7. Check Asset tab with the location (all the asset associate with the location will be
shown)
8. Save the new record
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4. Go to Craft Tab (we can associate labor in Craft or we can associate craft in
Labor).
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NOTE: Inventory is for spare parts (fast moving part), for example: seal, oil, oil filter,
bolt, nut, washer, etc. and Asset is for the equipment, such as Generator, milling machine,
pump, etc.
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6. Go to Inventory Inventory to check the item and to set the property of the
Inventory type
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1. Go to AssetsAssets
NOTE: Asset module is for equipments that the companies or organizations have. For
example: Production equipment, Facility equipment, Fleet, and IT equipment.
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Note: when we chose a parent for an Asset, it means that the Asset will become as a Sub
Assembly of the parent Asset.
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6. Save Record.
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Job Plan is a module that enable user to define the sequence of a job. For example: to
change the oil filter, we can create 3 sequences:
1. Open the machine cover.
2. change the oil filter.
3. Close the machine cover.
A job may have Job Plan or not. This Job plan is not a necessity for a job.
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3. Entering Job Plan Data (Job Plan CODE, Job Sequence, and Associating Labor,
Material and Equipment/Tools to Job Sequence/task) and save record
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Associating Labor
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Note:
We can associate 2 or more task with 1 Person or we can associate 2 or more person with
1 task
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Associating Material
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Associating Equipment/Tool
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Work order process life cycle occur when a work order is automatically or
manually generated.
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Scheduling information:
The filed in the scheduling information determine the status change in the work
order.
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Note:
- We can enter Job Plan in Job Details section if we have already define the job plan in
job plan application.
If not, we can define and create Job Plan in the Plans Tab.
- Shceduling information to determine the status change of the work order.
- Responsibility section is to enter person record related to work order.
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4. Go to Plans tab If we want to create a Job Plan or modify an existing Job
Plan.
NOTE:
This tab is the same like the one in Job Plan Module. Then, we can create Job Plan also
from work order module (if the job has a certain sequence (job plan) to be followed).
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7. Go to Actual Tab if we want to manage child work orders and task status as
well as reporting the actual resources.
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8. Go to Log Tab .
This tab is used to display Failure Code hierarchy based on the Asset Failure
Class.
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4. Go to Frequency Tab.
-
This tab is to determine PMs frequency scheduled that related to how often the
work orders are generated. It can be time-based (based on elapse time) and meterbased (based on mileage).
Active Days section allow to select the days of the week on work order can be
generated.
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7. Go to PM Hierarchy Tab.
-
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