S3 Enterprise21 screens
Maintenance
Keeping the machines running: breakdowns put right, planned service done before things break, the spares to do it with, and what it all costs. Every page in the Maintenance menu, what it is for, and where it leads; then the main records. The pictures are the demo company (Foundry Valves) after the test runs, so the names and numbers are made up. For the story, read How maintenance works first.
How maintenance work goes
The work
Breakdowns
Every maintenance order: the machine, what is wrong, when it was reported, how long it has been down, its kind (breakdown, condition, improvement, preventive), the technician and status. A machine down right now shows its time in red. Report a breakdown starts one.
Due
Preventive maintenance by when it falls due - by the calendar or by the machine's hours or strokes - and rounds missed. Its orders are made ahead each morning, or here with Make orders.
Rounds
The floor's checks across machines, ticked each day or shift: today's, and those missed the week before. A check not OK raises an order.
Calendar
The week's planned maintenance windows and the plans falling due, so planned stops can be lined up with production.
Equipment
Every machine and its state now (running or down), how critical it is (A stops the plant), open orders, MTBF and MTTR (how often it fails and how long a repair takes), and what it cost this year.
Spares
The spares each machine must have on the shelf - fitted, hold at least, what the stores hold (short in red) - and what was used, machine by machine.
Masters
Preventive plans
What each machine needs and how often - every month, every 50,000 strokes - with its checklist.
Service contracts
AMCs, warranties and on-call contracts for the machines: the vendor, the machines covered, the period, the cost, visits used.
Machines
The machines themselves (the same list as Items' Machines), where each stands, what it is part of, its cost centre.
Technicians
The floor people who do maintenance work, with their trade.
Places
Where things stand - a plant, a shop inside it - for machines and assets alike.
Problems
What can be wrong with a machine (hydraulic pressure low, spindle noise), picked when a breakdown is reported.
Causes
Why it went wrong (seal worn, bearing failure), picked when the order is done.
Remedies
What put it right (seal kit replaced), picked when the order is done.
Reports
Maintenance reports
How the machines held up and what keeping them running cost: by machine (breakdowns, hours down, availability, MTBF, MTTR, spares, service), breakdowns by problem and by cause, cost by kind of work, hours booked.
Maintenance budget
The year's maintenance budget by machine against what was spent - spares, labour, service, outside orders - and month by month.
Settings
Maintenance options
The cost of an hour of maintenance work, whether a lapsed statutory certificate stops work on the machine, and after how many minutes an unstarted breakdown of a critical machine is escalated.
The main records
Maintenance order
The breakdown up top: machine, work centre, when reported and stopped, when it ran again, how long it was down, its priority, and The machine's history. Tabs: The work (technician, cause, remedy, outside service, what was done, its tasks) · Spares and outside work (parts, what was bought for it, spares issued, and a warranty claim when the machine is under warranty) · What it cost (spares, outside service, labour)
Equipment
One machine: maker, model, serial, supplier, installed and warranty dates; its counters and measures (a bearing temperature with its limit); statutory certificates; every order on it; its critical spares. History card prints its life; Report a breakdown starts an order.
Preventive plan
The machine, how often, how many days ahead its order is made, who does it, how long it takes, whether the machine stops for it - and its checklist with what each check expects. Checklist sheet prints it.
Round
A route of checks across machines: the plant, how often it is walked, by whom, and each check - the machine, inspect or read, what.
