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  • 1.  Issue Forecasting Meter-Based PM's

    Posted 08-21-2024 10:27

    The meter we are using is RUNHOURS

    Specifically, a situation where a piece of equipment may only run intermittently (not a full 24hrs. a day) Sometimes of our compressor units do not run for several months in a row, then are started up, and then run for several months…and so on.

    Our issue is the way Maximo forecasts the next PM here.

    Maximo calculates the Estimated Next Due date using the following formula:

    Last comp date *Plus* Remaining days (assuming that none of 'Work Order Generation Information checkboxes are selected)

    When forecasting, Maximo references the last completion date of the PM, then takes the "units to go', converts it to days, and adds that to the last completion date to create the forecast date.

    (**To me, this is wrong. This is like getting your oil changed, parking your car for several months and then calculating your next oil change date based on the last oil change date. Shouldn't we calculate how many kilometers we have left on the interval from NOW, not then.) 

    In our mind it should use the system date, then take the "units to go', convert it to days, to create the forecast date.

    (Note: We understand that this can only be forecasted when the intermittent use equipment is running.)

    We use forward-looking forecast reports for planning and budgeting. These are often PMs with long frequencies (such as overhauls)

    The way Maximo is forecasting is throwing off the correct 'next due date' by several years, in some cases. This means we can't trust Maximo to give us the correct forecast information for meter-based PMs.

    Has anyone else dealt with this? Looking for any suggestions or advice that anyone has out there on this topic.


    #WorkManagement

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    Becky Wigemyr
    Torxen Energy
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  • 2.  RE: Issue Forecasting Meter-Based PM's

    Posted 08-23-2024 11:07
    Edited by Christopher Winston 08-23-2024 14:02

    Hi Becky,

    Some questions:

    1: Does the PM also have a calendar based frequency, or just the meter based frequency?

    2: The PM is set up as  "floating"? "Use Last Work Order's Start Date to Calculate Next Due Date?" is not selected

    3: For the associated meter, what is the "Average Calculation Method"?

    4: Do you delete your forecasts on a daily basis and reforecast?

    Regards,

    Steve



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    Steve Norris
    Cohesive
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  • 3.  RE: Issue Forecasting Meter-Based PM's

    Posted 08-26-2024 09:17

    Hi Steve, thank you so much for getting back to me. Here are the answers to your questions.

    1: Does the PM also have a calendar-based frequency, or just the meter-based frequency?

    No. I think what you are asking is, does it have an 'Either/Or" type set-up, and the answer is no. We only have the meter-based frequency set up.

    2: The PM is set up as "floating"? "Use Last Work Order's Start Date to Calculate Next Due Date?" is not selected.

    Yes, it has been set us as 'floating". All checkboxes are deselected under "Work Order Generation Information".

    3: For the associated meter, what is the "Average Calculation Method"?

    The "Average Calculation Method" is "SLIDING-DAYS".



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    Becky Wigemyr
    Torxen Energy
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  • 4.  RE: Issue Forecasting Meter-Based PM's

    Posted 08-26-2024 11:47

    Hi Becky,

    You are quite welcome. Can you please confirm the following.

    1: You confirmed the "Average Calculation Method" is "SLIDING-DAYS", how many days?

    2: How are meter readings imported into Maximo, and how often?

    3: Do you delete your forecasts on a daily basis and reforecast?

    Thanks,

    Steve



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    Steve Norris
    Cohesive
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  • 5.  RE: Issue Forecasting Meter-Based PM's

    Posted 08-26-2024 12:20

    Hi Steve,

    Here are my answers 😊

    1: You confirmed the "Average Calculation Method" is "SLIDING-DAYS", how many days?

    42 Days is the number we are using

    2: How are meter readings imported into Maximo, and how often?

    We are bulk loading the meter reading once a week, using MX Loader.

    3: Do you delete your forecasts on a daily basis and reforecast?

    We have a Crontask that deletes and then re-runs the forecast every 5 minutes.



    ------------------------------
    Becky Wigemyr
    Torxen Energy
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  • 6.  RE: Issue Forecasting Meter-Based PM's

    Posted 08-27-2024 10:13

    Hi Becky,

    Additional comments/questions

    1: You confirmed the "Average Calculation Method" is "SLIDING-DAYS", how many days?

    42 Days is the number we are using

    Is the average units per day accurate from your perspective?

    2: How are meter readings imported into Maximo, and how often?

    We are bulk loading the meter reading once a week, using MX Loader.

    Once the meter readings are uploaded, the PM next due date(units to go/average units per day) should be updated based on the increased Meter Life to Date values. 

    3: Do you delete your forecasts on a daily basis and reforecast?

    We have a Crontask that deletes and then re-runs the forecast every 5 minutes.

    May I ask why the frequency is every 5 minutes? Also, please confirm you are utilizing an escalation to delete the forecasts? Simply re running the out of the box(OOTB) PM forecast cron task will not delete the existing forecasts, which are "static" and do not update based on increased meter life to date values, a change in the average units per day value, or when an open work order previously generated from the PM is completed. 

    Regards,

    Steve



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    Steve Norris
    Cohesive
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  • 7.  RE: Issue Forecasting Meter-Based PM's

    Posted 08-27-2024 11:38

    Hi again Steve, thanks for your help.

    Is the average units per day accurate from your perspective?

    Yes, it looks good to us.

    2: How are meter readings imported into Maximo, and how often?

    We are bulk loading the meter reading once a week, using MX Loader.

    Once the meter readings are uploaded, the PM next due date (units to go/average units per day) should be updated based on the increased Meter Life to Date values. 

    Yes, this is all happening as it should. Everything updates. The problem is with the estimated next due date/forecast dates.

    What I need to know is if for meter-based PMs, to populate the 'Estimated Next Due Date' Field, does OOTB Maximo use the 'Last Work Order Start Date' plus 'Units to Go' to create the date in the field?

    Or

    Does OOTB Maximo the 'System Date' (today's date) plus 'Units to Go' to create the 'Estimated Next Due Date' in the field?

    3: Do you delete your forecasts on a daily basis and reforecast?

    We have a Crontask that deletes and then re-runs the forecast every 5 minutes.

    May I ask why the frequency is every 5 minutes?

    This was a request by our planner so that any changes made in the PMs was reflected rather quickly in the system. I think the Cron task is working well, but I have asked about the escalation.  



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    Becky Wigemyr
    Torxen Energy
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  • 8.  RE: Issue Forecasting Meter-Based PM's

    Posted 08-27-2024 13:46

    Hi Becky,

    See my responses below

    What I need to know is if for meter-based PMs, to populate the 'Estimated Next Due Date' Field, does OOTB Maximo use the 'Last Work Order Start Date' plus 'Units to Go' to create the date in the field?

    Or

    Does OOTB Maximo the 'System Date' (today's date) plus 'Units to Go' to create the 'Estimated Next Due Date' in the field?

    For "Fixed" PMs, "Use Last Work Order's Start Date to Calculate Next Due Date?" = Checked, the PM next due date is calculated based on Last Start. The PM will always have an estimated next due date.

    For "Floating" PMs, "Use Last Work Order's Start Date to Calculate Next Due Date?" = Unchecked, the PM next due date is calculated based on Last Completed. The PM will not have an estimated next due date if there is an open PM work order 

    For meter based PMs, the "reading at last work order value" is used as a reference point. This is the meter life to date value on the date(or closest meter reading date) when the PM work order was last created or when the PM work order was last completed. "Last Work Order Information" section, "Meter Reading" field

    Meter based PMs are next due based on a calculation of:

    1. Next Meter Reading-Current Meter Life To Date=Units to Go

    2. Units to Go/Average Units per Day=Days To Go(not displayed in the Maximo UI just used in the calculations)

    3. Today's date + Days to Go=Estimated Next Due Date

    Here is the "rub" with PM Forecasts, if the PM is "Floating" and there is an open PM work order, the PM forecast will be based on completing the work order the day of pm forecasting. Forecasting after the open PM work order is completed will be based on Last Completed. This is why it is critical to delete existing forecasts on a regular basis as forecasts are static and will not dynamically update as work orders are completed. Existing forecast dates "win" over the PM's estimated next due date

    Please let me know if this answers your questions.

    Regards,



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    Steve Norris
    Cohesive
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  • 9.  RE: Issue Forecasting Meter-Based PM's

    Posted 08-27-2024 14:46

    Steve, thank you for this. This makes perfect sense to me and helps me understand better. As always, you hit it out of the park. I really appreciate your expertise and ability to explain things. Hope to see you at CanMUG. 



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    Becky Wigemyr
    Torxen Energy
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  • 10.  RE: Issue Forecasting Meter-Based PM's

    Posted 08-27-2024 20:03
    Edited by Craig Kokay 08-27-2024 20:55

    Hi Becky,

    There are lots of nuance to the art of getting meters working.  You'd think that it's just tick the "Generate Work Order Based on Meter Readings (Do Not Estimate)?" and also the uncheck the "Use Last Work Order's Start Date to Calculate Next Due Date?", which is great unless you then add the forecast into the mix.  As Steve has pointed out that once you do have a forecast, it wins, and if the Average Units/Day changes, the next date of the following PM does not change i.e. it's also most as if its acting like a fixed PM.  Therefore, it's important to delete the forecast and do a new forecast.  It's important to note that these are two different operations, though why it's not built into the forecast code is another matter.  You do need to leave enough time between these operations depending on how far out you're forecasting and the performance of your infrastructure.  This is even more important when you involve Maximo Scheduler and rolling schedules as any rolling must occur after the reforecast.

    I am hesitant also, like Steve, that there is ever a need to run the reforecast every 5 mins.  I say this because the PM WOGEN is not running with the same frequency, nor should it.  Once a day is more than enough (usually) for all the above operations.  Planners do not deal with the near-term, that is the realm of the Scheduler and even then, once a day is enough.  Now there is one more Cron task to ensure is running after the reforecasting.

    Order of operations, once a day:

    1. Delete forecast
    2. Reforecast
    3. Run PMWOGEN.  Note: use the leadtime (day based) or/and Generate WO Ahead By (for meters) to control how far (if any) in advance of the due date to generate the PM
    4. Run rolling cron task so this takes into account any newly generated work orders

    Your use case of inconsistent asset usage and therefore meter reads is not unusual, and unless you know these little traps when you have a forecast, it throws of the schedule as Maximo is assuming linear usage.

    One thing, even though the asset is out of service or idle, part of the secret is to still take and enter new meter readings on a regular basis (if possible) as the latest meter reading and date as taken into account.



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    Craig Kokay
    Principal Consultant
    COSOL

    email: craig.kokay@cosol.global
    #IBMChampion
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  • 11.  RE: Issue Forecasting Meter-Based PM's

    Posted 08-28-2024 12:20

    Hi Craig/Becky et all,

    We recently had an issue with a client where their cron task schedule did not account for the possibility of night shift workers completing PM work orders after the PM forecast had run, but prior to the pm wogen being run. We advised them to change their daily cron task/escalation sequences as follows:

    1: Delete PM Forecast

    2: Run PM WOGEN

    3: Run PM Forecast

    4: Run PM Forecast Cost

    Regards,



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    Steve Norris
    Cohesive
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