Preventive maintenance by days, hours or cycles
Each machine gets maintenance plans that fall due by the calendar, by its running hours or by the pieces it has made. A due plan raises a maintenance request with its checklist and spares, and closing the request costs it and moves the plan on.
PLANSFrom Growth
The problem it solves
- Oil changes and belt checks are done when someone remembers, so a press runs past its service and breaks in the middle of an order.
- A machine that runs three shifts needs service sooner than one that runs one, but the plan on the wall counts only weeks.
- Spares are taken from the store for maintenance with no slip, and stock never matches.
- Nobody can tell what a machine's upkeep costs in spares and technician time.
How it works
- Link each piece of equipment to its machine or station. Its Hours Run and Cycles Made then come from production by themselves.
- On the equipment, add maintenance plans: Every So Many Days, Running Hours or Cycles, and how often. Add the checklist, the spares, the team, the technician and how long it takes.
- Each day the system raises a preventive request for every plan that is due, unless one is already open. You can also press Raise Request Now.
- The technician is told at once. On the request they tick the checklist, write what they found, and press Issue Spares to take the spares out of stock.
- When the request reaches a done stage, it is costed (spares plus technician time). The plan starts counting again from that day and meter reading.
Everything it does
Equipment and meters
- Equipment is Odoo's maintenance equipment, with a Machine / Station field and a Maintenance Plans tab
- Hours Run: productive and performance time recorded on that machine
- Cycles Made: the quantity produced on finished work orders of that machine
- Meters show only when the equipment is linked to a machine
Maintenance plans
- Trigger: Every So Many Days (the default), Running Hours or Cycles
- Every: 30 to start with
- Checklist lines (Check / Do), spares with quantities, team, technician, Takes (hours): 1 to start with
- Last Done On and Meter When Last Done, filled when a request is closed
- Meter Now, Next Due On (for days), Left Before Due (days, hours or cycles; below 0 is overdue) and Due
- A Due filter on the list; overdue plans are shown in red
- Raise Request Now; a plan never has two open requests at once
- Plans can be archived; each plan belongs to one Entity
The request
- A preventive request named after the plan and the equipment, scheduled now, with the plan's duration, team and technician
- Checklist tab: each line with Done and Found
- Spares and Cost tab: spares used, Issued, the stock transfer, From Plan and Meter When Raised
- Issue Spares makes a stock transfer from the Entity's warehouse to a Spares Used location. It is validated by itself when all spares are in stock and not tracked by lot
- Cost: Spares (at stock value) plus Technician Time (the request's duration at the Entity's technician cost per hour)
Dashboard
- A ready Maintenance dashboard for technicians and production managers. It shows open breakdowns, planned jobs open, jobs done, active plans, open requests by machine and requests per day
What it does not do
- No readings typed by hand, and no meter from machine controllers (PLC): hours and cycles come only from production recorded in SmartMy
- A plan by days does not move to skip Sundays or holidays
Who uses it
Maintenance TechnicianSets up plans, works on the requests, ticks the checklist and issues spares.
Production ManagerSees the Maintenance dashboard, what is due and what each machine's upkeep cost.
Manufacturing AdministratorSets the technician cost per hour and links equipment to machines.
StorekeeperCompletes the spares transfer when a spare is short or tracked by lot.
Where you use it
- Web: Maintenance > Maintenance > Maintenance Plans, and the equipment form's Maintenance Plans tab
- Web: Maintenance Requests, with the Checklist and Spares and Cost tabs
- The SmartMy Manufacturing app: Repairs, to tick the checklist, add a note and mark the request done. Built and in testing, not in the app stores yet
- Not on the shop floor terminal: operators raise breakdowns there, not planned work
What you control
Settings
- Per plan: trigger (Every So Many Days to start with), every 30, takes 1 hour, technician and team
- Technician cost per hour: in Settings > Manufacturing, empty to start with (time is then costed at nothing)
- The daily job that raises due requests: on, once a day
Notifications
- Maintenance Request: to the request's technician, or else every Maintenance Technician of the Entity, when a plan raises a request. In the app inbox and by email (app push built in, not switched on yet). It goes out at once; a person can switch off email but not the event
Questions
Can a plan fall due by the pieces a machine has made?
Yes. Choose Cycles: the count is the quantity produced on finished work orders of that machine. Running Hours uses the productive time recorded on it.What if a request is already open when the plan falls due again?
No second request is raised. The plan waits until the open one is closed, then counts again from that day and meter reading.Are spares taken out of stock?
Yes. Issue Spares makes a stock transfer to a Spares Used location. It completes by itself when everything is in stock and not tracked by lot; otherwise the store finishes it.How is a request costed?
When it reaches a done stage: spares at their stock value plus the request's duration at your technician cost per hour from Settings.Can we read hours from the machine's controller?
Not yet. Machine data from PLCs is not offered; hours and cycles come from production recorded on the terminal and work orders.Is it in Starter?
No. Maintenance plans start in Growth.Related features
PLANNING, QUALITY AND COSTBreakdowns raised from the floor, spares and technician time costedWhen an operator stops a machine at the terminal for a breakdown reason, a repair request opens for that machine at once. The maintenance team is told. The stop time and the repair sit on one record, and the repair is costed in spares and technician time.LINES AND SCHEDULINGOEE per machine and day, and the machine board on a TVOEE is worked out every hour for each machine and day from its running time and the pieces counted at the terminal. It is split into availability, performance and quality. A machine board on a TV shows every machine as working, stopped or idle.PRODUCTION AND JOB WORKTools, dies and moulds with their life and serviceKeep each mould, die, jig and fixture with its pieces per shot, its life and its service interval. The right tool is put on each job and its shots are counted when the job finishes. It is flagged for service and near the end of its life.SHOP FLOORThe shop floor terminal: a tablet at each machineA tablet at each machine or station shows its jobs in big tiles. Operators sign in with a PIN or badge, and start and pause jobs. They count good and rejected pieces with a reason, and stop the machine with a reason. Every count goes straight into the order.PLANNING, QUALITY AND COSTThe SmartMy Manufacturing appAn Android and iOS app for supervisors, quality inspectors and maintenance technicians. It has today's figures, production orders, machines and jobs, andon calls, quality checks and repairs. Each is shown to the people whose role allows it. Operators keep working on the terminal.ACROSS SMARTMY MANUFACTURINGDashboardsManufacturing opens on ready dashboards for each role. The supervisor sees what is running and waiting for material, and the planner sees the order book. Job work, quality and maintenance each have their own. Every number is counted for the person looking, and a click opens the records behind it.
See your shop floor on it.
Tell us what you make, how many machines and people you run, and how production is recorded today. We will set up a line with you and run a job on the terminal.