PM Overview

Process Review
Plant Maintenance
Master Data
Order Creation & Processing
Preventative Maintenance
Gage Calibration
Confidential – Copyright 2007

Deere & Company
Worldwide Agricultural Division
Chapters
The topics presented in this course include:

– Technical Objects
• Functional Locations
• Equipment
– Maintenance BOMs
• Material BOMs
• Equipment BOMs
– Work Centers
– Document Links

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Functional Location
• Functional location should represent the work team or

physical location within a plant where maintenance tasks
are performed.
• Functional locations are organized in a hierarchy.
• Work Orders and Preventative Plans may be created for
Functional Locations (i.e. Facilities)
• Equipment can be assigned to a functional location.
• Functional locations use a defined naming convention
called a structure indicator. For example the structure
could be:
– Plant > Site > Department/Facility > Equipment Type

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Functional Location
• Functional locations can be used to do cost

analysis.
– Maintenance costs for equipment installed at a
functional location will be rolled up to that functional
location allowing cost analysis at the highest levels.
• Functional location master can contain:
•Location •Organization
•Maintenance Plant •Company Code
•Location •Cost center
•Plant Section •Planner Group

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Creating a Functional Location – IL01
• Structure Indicator
• The new functional location will inherit the values
of its superior functional location as long as the
structure is the same.

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Ottumwa Facilities Structure

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Ottumwa Installed Equipment Structure

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Ottumwa Miscellaneous Locations

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Equipment – Creating of Required When:
• Preventative Maintenance or Repair type orders

need to be written against it.
• Maintaining specific information for equipment:
– Manufacturer/Vendor information (model, serial, etc)
– Acquisition value / date etc.
– Warranty
• The costs and reasons for performing
maintenance needs to be monitored and
reported.
• Functional location assignment history is needed

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Creating Equipment

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Maintenance BOMs
• BOMs are a list of the components (spare parts)

making up a technical object (equipment) or an
assembly (IBAU material).
• Used for Spare Parts (materials) Planning
– For orders or task lists, you can identify and plan to use
spare parts that exist in the bill of material.
• The three types of Maintenance BOMs are:
– Functional Location BOMs
– Equipment BOMs
– Material BOMs
• Parts purchased for equipment will not be
automatically added to BOMs.
– Maintain the BOM manually to add or delete any material.
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Work Centers
• Skilled trades group that carry out maintenance work

• Uses of Work Centers:
– Operations within a work order specify work centers
necessary for the task
– Scheduling – Work center Working times and shifts impact
the work order start dates.
– Costing – Costs are calculated based from the cost center
and activity type assigned to the work center.
– Capacity Planning – based on the number of people and
shifts assigned to the work center.
– Linking to HR – Employees in HR can be linked to work
centers.
Confidential
© Deere– & Copyright
Company 20072008
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Order Creation & Processing
General Create and View

Plant Maintenance Work
Orders

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Creating & Viewing Maintenance Work Orders
 Why do we create work orders?

 Track cost and history
 Improve machine reliability and uptime
 Prioritization of work order backlog queue
 Examples of when you might create a work order

 Machine down
 Request project work (Ex: new guard rail)
 Replace a light

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Basic steps to create an “EasyEntry” Work Order
Execute
ZI_EASYENTRY
Creating Easy Entry WO

Step 1 Execute ZI_EASYENTRY
Step 2 Select Equip or FL
Step 3 Select Order Category
Step 4 Selections from 4 menus
Step 5 Add WO description; Review; Save

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Select Equipment or Functional Location Creating Easy Entry WO


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Step #3 – Select Order Category Creating Easy Entry WO

1. For the “Order Category” section, “Repair” is the
default (can only select one)
2. Each radio button is

associated with a specific
order type.
Order Type Planned /

Unplanned
##M3 Planned
##M1 Unplanned
##M3 Planned
##M6 Planned

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Selections from 4 menus

Menu #2:
Electrical
control objects
Menu #1:
Major objects
for a Laser

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Step #4 – Selections from 4 menus

Menu #3: List of Step 2 Select Equip or FL
problem catalogs Step 3 Select Order Category
for a Laser Step 4 Selections from 4 menus
Menu #4: List of

more detailed
electrical problems
Note:
Each Equipment or Functional
Location can provide different
menu selections through a Catalog
Profile

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Step #5 – Add WO description; Review; Save Creating Easy Entry WO

1. Type in work
order description

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Creating “EasyEntry” Work Orders – Normal Scenarios
More on a Functional Locations

• Used by Plant Maintenance module to represent an area, location, or process
• A piece of master data similar to an equipment master
• Equipment can be associated (installed) to a Functional Location

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It can represent a department

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It can represent a building

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Searching for Maintenance Work Orders
Work Order Status
REL Released Labor & Materials can be charged
PCNF Partially Confirmed Labor Charged; work remaining
CNF Finally Confirmed Labor Charged; all work complete
TECO Technically Complete Work Order is complete
CLSD Closed Work Order closed by batch job if

TECO > 90 days

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Execute IW39

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IW39 – Example #1:

List of open work orders created by RACF
CS70735, for the Davenport Works (DW01) For all open orders
(status REL)

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List of open work orders for equipment

114164 at the Davenport Works

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IW39 – Example #2:

List of open work orders for equipment
114164 at the Davenport Works

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Order Processing
Plant Maintenance
Execution

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Plant Maintenance Execution
 Work Order Types

 Work Order Cycle processes and transactions
 Work Order Selection
 Work Performed
 Charging Labor and Closing
 Emergency / Breakdown Orders
 Sub-Order Work Order (IW36)
 Summary of using IW37

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Work Order Cycle
Work Order Cycle

Production Work Order Creation Work Order Selection Work Performed Charge Labor & Close
Add operation
IW37  IW32
Find Work Order Repair Parts and/or Services Needed

IW37  Report Variant
Create Work Order
Material or Equip BOM
Functional ZI_EASYENTRY
IW32  Components  List Charge Labor / TECO
Location Arrive on Work Order
IW37  IW41 or IW42
IW37  IW41 Find Material
ZM_MAT_STOCK
Assign Work Order

Equipment
IW37  IW32 Goods Issue
IW37  IW41  Goods Movements
Viewing Confirmations
IW47
Work Order Print / • Requisition (UnNumbered / Non-stock)

Print Preview • Requisition (Numbered / Non-stock)
IW37  IW32 IW32 Components
Requisition (Services)
IW32 Operations
Maintenance Request Execution Completion

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Work Order Cycle  Work Order Selection  Find Work Order
Work Order Cycle

Add operation
IW37  IW32

Create Work Order
ZM_MAT_STOCK
Assign Work Order

Equipment
IW47

IW32 Operations

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IW39 – Display PM orders:

Selection of Orders
Display Change
Orders IW39 IW38
Order Oper IW49 IW37
IW37 – Change Operations:

Selection of Order Operations

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IW37 – Example #2: List of DW01 open CFM1 “Emergency

/ Breakdown” work orders for equipment 121796
Confidential – Copyright 2007 35

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Work Order Cycle  Work Order Selection  Arriving on Work Order
Work Order Cycle

Add operation
IW37  IW32

Create Work Order
ZM_MAT_STOCK
Assign Work Order

Equipment
IW47

IW32 Operations

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From IW37, enter work center and plant
Select the line with your work order
REL

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Confirmation Screen Enter SAP Personnel Number

Save
Zero hours
Back on the IW37 list, after refreshing

New status of PCNF, and zero actual work hours
Note: It is the combination of status PCNF and zero actual

Confidential – Copyright 2007 work hours that tells us someone has arrived on the work order
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Work Order Cycle  Work Order Selection  Assigning Work Order
Work Order Cycle

Add operation
IW37  IW32

Create Work Order
ZM_MAT_STOCK
Assign Work Order

Equipment
IW47

IW32 Operations

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IW37 list of work orders, select

line with your work order… Click the “Order” button Order screen
Add the SAP ID of the

employee to be assigned to
this work order…then Save…

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Back to the IW37 list of work

order operations (after refresh)
First operation now has SAP ID 614125 assigned to it

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Work Order Cycle  Work Order Selection  WO Print / Print Preview
We will now show how to print preview a work order, and direct it to a printer.
Work Order Cycle

Add operation
IW37  IW32

Create Work Order
ZM_MAT_STOCK
Assign Work Order

Equipment
IW47

IW32 Operations

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IW37 select line “Order” button “Order” screen
Menu: Order  Print  Order

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default line selected is the 2010 line Or use OVER to select a printer manually
This will print to the printer designed
for the skilled trades work center

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Print Preview

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Work Order Cycle  Work Performed  Adding an Operation DW
We will now review the process for adding another operation to a work order.
Work Order Cycle

Add operation
IW37  IW32

Create Work Order
ZM_MAT_STOCK
Assign Work Order

Equipment
IW47

IW32 Operations

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Work Order Cycle  Work Performed  Adding an Operation
IW37

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Enter description for

the new operation
Enter long text

if desired

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To assign a person to each operation using

their SAP HR ID, select both operations
Navigation arrows
Add the personnel number

(SAP HR ID) for each operation

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IW37 we do not see the new operation of 0020

Filtered on work center M90-709…and E90-703 was added to oper 0020
Adding work center E90-703 to the filter

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Work Order Cycle  Work Performed  Material or Equip BOM
2 recommended ways to find Preferred method viewing a

an indirect part. material or equipment BOM
Work Order Cycle

Add operation
IW37  IW32

Create Work Order
ZM_MAT_STOCK
Assign Work Order

Equipment
IW47

IW32 Operations

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Environment  BOM item  Material stock

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Double click on the Material

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Work Order Cycle  Work Performed Material or Equip BOM
To check stock, you

can click the “Material
Availability” button
Another way to check

stock is the Storage
Location field matchcode

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Difference between a material BOM and an equipment BOM?
Equipment BOM Material

is assigned directly to the
equipment Equipment BOM
Material BOM material Material BOM

is assigned to a
“Construction Type”
The Construction Type
is assigned to the
Equipment

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Work Order Cycle  Work Performed  Find Material (ZM_MAT_STOCK)
Find a part using transaction ZM_MAT_STOCK
Work Order Cycle

Add operation
IW37  IW32

Create Work Order
IW37  IW41
Find Material
ZM_MAT_STOCK
Assign Work Order

Equipment
IW47

IW32 Operations

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ZM_MAT_STOCK
Material Types
• ERSA - Spare Parts
• Repair parts; belts; bearings; pumps
• HIBE – Operating Supplies
• Office / cleaning supplies
• FHMI – Production Resource & Tools
• Grease; perishable tools, gages; fixtures; dies
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Work Order Cycle  Work Performed  Goods Issue
Getting a repair part out of a crib.
Work Order Cycle

Add operation
IW37  IW32

Create Work Order
ZM_MAT_STOCK
Assign Work Order

Equipment
IW47

IW32 Operations

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From IW37, select WO and click on the

“Individual confirmation” button

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Click the Save button

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SP01 to preview the pick ticket

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Storage
Warehouse Type Bin Location
Part description
Part number
Work Order Number

Storage Type
Description Code
Barrel Crib BRL
Central Crib CTL
Electrical Crib ELC
300 Old Shot Blast OSB
Pipe Fitters Crib PFT
Vertical Towers VRT
Transfer Order Number

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Work Order Cycle  Work Performed  Req (Unnumbered Non-Stock)
Creating a requisition for a part that does not

have a material master, and is not stocked.
Work Order Cycle

Add operation
IW37  IW32

Create Work Order
ZM_MAT_STOCK
Assign Work Order

Equipment
IW47

IW32 Operations

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“N” for Non-Stock in the Item

Category (IC) field

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Work Order Cycle  Work Performed  Req (Numbered Non-Stock)
Requisition for an indirect part with a

material master but is not normally stocked.
Work Order Cycle

Add operation
IW37  IW32

Create Work Order
ZM_MAT_STOCK
Assign Work Order

Equipment
IW47

IW32 Operations

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Note: This process can be used for a part that…

1. Has a material master and is not stocked
2. Is normally stocked, but you want to order some without touching the crib inventory
“N” for Non-Stock in the Item

Category (IC) field

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Work Order Cycle  Work Performed  Req (Services)
We will now review the process for creating a requisition for an outside contractor.
Work Order Cycle

Add operation
IW37  IW32

Create Work Order
ZM_MAT_STOCK
Assign Work Order

Equipment
IW47

Print Preview • Requisition(Numbered / Non-stock)
IW32 Operations

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Purchase Requisition from the work order for outside services

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Changing the control key to PM02

triggers the purchasing screen

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Work Order Cycle  Charge Labor & Close  Charge Labor / TECO
Charge labor hours to a work order and technically complete (TECO)
Work Order Cycle

Add operation
IW37  IW32

Create Work Order
ZM_MAT_STOCK
Assign Work Order

Equipment
IW47

IW32 Operations

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Charging labor to a work order
Enter your personnel number

and hours
then save
After refresh

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Charge labor hours to a work order, immediately TECO (Technically Complete) it, and fill in the Cause catalog.
From IW37
Every operation on every work order must be “Finally

Confirmed” upon completion
This drives the Actual End date on the work order which
will be used on metrics reports.
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Back on IW37

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Work Order Cycle  Charge Labor & Close  Viewing Confirmations DW
Work Order Cycle

Add operation
IW37  IW32

Create Work Order
ZM_MAT_STOCK
Assign Work Order

Equipment
IW47

IW32 Operations

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Work Order Cycle  Charge Labor & Close  Viewing Confirmations DW

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Emergency / Breakdown ##M1 Work Orders
Emergency WO starts the breakdown clock IW42

to TECO the order and stop the breakdown clock
##M1 Work Order
Malfunction start date and times were populated based

on when the order was created and saved.

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Emergency / Breakdown CFM1 Work Orders DW
After charging labor

hours and completing
the order (TECO)
Malfunction End date

and time and duration
populated form
completing the order

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Creating a sub work order DW
Scenario #1 for creating sub order:

An emergency order (##M1) needs to be closed after the
machine is up and running, but there is more work to do that
should be associated with the original breakdown order.
The machine has been fixed, but before this

order is closed create a sub-order for further
needed work… IW36

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Creating a sub work order
Scenario #1 for creating sub order:
An emergency order (CFM1) needs to be closed after the
machine is up and running, but there is more work to do that
should be associated with the original breakdown order.
Enter the
description in
the sub-order
Note: the status is Created

(CRTD), click “Put in Process” to
simultaneously REL and save
After saving, the

superior order can
be completed

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Order Processing
Preventative Maintenance

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Preventive Maintenance - Overview
• Preventative maintenance is used to avoid breakdowns.

• It is the generic term for planned inspection and
maintenance.
• Within Preventative Maintenance you can plan time and
materials in advance.
• There are two types of maintenance planning:
– Time Based – maintenance is performed in specific time cycles,
like monthly or semi-annually.
– Performance (Usage) Based – maintenance is performed based
on performance or usage readings of instruments that monitor
the equipment.
• For example, a vehicle should be serviced every 100 usage
hours; the usage information comes from an hour meter
attached to the vehicle.

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Preventative Maintenance Master Data

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Maintenance Plan – Definition
• Description of the maintenance and inspection tasks to

be performed on equipment or functional locations. The
maintenance plans describe the dates and scope of the
tasks.
• Contains the Maintenance Cycle or trigger when the
maintenance must take place. The trigger can be time
based or performance based.
• Maintenance plans must have at least one Maintenance
Item. A Maintenance Item contains the technical
object(s) and usually will be assigned a task list.

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Task List – Definition
• Describes the sequence of individual maintenance

activities which must be performed.
• Task lists can be used for preventive maintenance and
routine work. They can also specify the required
material to carry out the operation as well as the time
needed to perform the work.
• A task list can be created specifically for an equipment or
functional location or can be general and reused on
multiple equipment and/or functional locations.
– Equipment Task List
– Functional Location Task List
– General Task List

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Measuring Points and Counters
• Measuring Point – physical or logical location where an

equipment characteristic is measured.
• Counter – tools that you use to represent the wear and tear
of an object, consumption, or the reduction of an object‟s
useful life. For example, an hour meter on a machine.
• Measuring Points use SAP characteristics to describe the
attributes of measurement.
– A characteristic describes what is being measured, and what the
unit of measure is (i.e. Hour Meter in Hours or Caliper Reading in
Inches).
• Measurement Documents are created from Measuring
Points. The results are stored in SAP and can be used to
trigger maintenance.
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Flow for Time Based Planning
Need to Generate
Does
PM’s for
Equipment
Equipment based
exist in SAP?
on Time
No
Yes
Create
Create Plan
Equipment
(IP41)
( IE01)
Create Task List

(Optional)
(IA01 - Equipment
IA05 - General/Generic Task list
IA11 - Functional Location task list)
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Flow for Usage Based Planning
Need to Generate
PM’s for
Equipment based
on Usage Get Annual Get Latest
Usage Reading with
Estimate Date
Create
Create
Does Measurement
Measuring Create Plan
Equipment Yes Document
Point (IP41)
exist in SAP? (IK11 Single Entry
(IK01)
IK34 Collective)
No
Create
Equipment
Create Task List
( IE01)
(Optional)
(IA01 for Equipment
IA05 for General/Generic Task list)
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Time Based Preventive Maintenance Execution
Weekly Plan
Yes
Work Order
Run of Triggered? Created
Batch Job
(Auto)
No
No Work
Order

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Time Based Preventive Maintenance Execution
How Time Based Preventative Work Orders

are Scheduled
– A Batch Job Runs Automatically
• Orders are Created from Batch Job
– Time is used as a trigger for order creation.
– The “Cycle” and „Call Horizon‟ in the maintenance plan
is used to set the frequency and the call dates when the
orders are created.
– Orders can be automatically printed to a specified
printer.

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Usage Based Preventive Maintenance
Execution
Enter Latest Reading
Against Equipment /
Measuring Point
(IK11)
Weekly Plan
Yes
Work Order
Run of Triggered? Created
Batch Job
(Auto)
No
No Work
Order

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Usage Based Preventive Maintenance
Execution
How Usage Based Preventative Work Orders are Scheduled
 A Batch Job Runs Automatically
 Orders are Automatically Created
 Measurement document readings plus

Measurement point annual usage estimates
§ The Trigger is when the estimated reading total meets or exceeds the cycle specified in the maintenance
plan.
 The “Cycle” in the maintenance plan is used to set the frequency.

 The “Call Horizon” determines how early the order is created
(default is 100% - or on time)
 The SAP system creates “Call Dates” from a combination of the
readings and annual estimate.
 Orders can be automatically printed to a specified printer.

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Plan Scheduling Maintenance
• A batch job automatically schedules the plan,

but a tool is available to make changes to the
schedule – transaction IP10 (Schedule
Maintenance Plan).
• You can use IP10 to:
– Change the date of a call
– Skip a call
– Manually trigger a call

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Scheduling Overview
• SAP offers following scheduling overviews:

– Graphical (IP19)
• Maintenance schedule
• Capacity load
– As List (IP24)
• Both views can display historical call information
• IP19 & IP24 can show the future order creation
dates (call dates)

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Order Processing
Gage Calibration
Gage Calibration Overview
Master Data
Gage Calibration Processing

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Gage Calibration Process Flow
New
Material Master
Yes
Create Indirect Material
Master For New Gage
QM/PM - Gage Calibration Processing
required for
gage? MM01 MIS Group
REVIEW CATEGORY
Transactions in SAP
Auto Usage Decision -
Gage's Status updated Closes Insp. Lot & PM Order
Updates Gage's Status &
Calibrated Date updated Plan's Calibrated Date
QA11 Batch / QE
REVIEW CATEGORY
No Create Equipment Master
For New Gage
(with Object Type=G)
Inspection Of Gage &
IE01 MIS Group Repair The Gage & Results Recorded
Return To Calibration Area On Characteristics
REVIEW CATEGORY
(repair If Req'd)
PM Order Inspector QE53 Inspector

REVIEW CATEGORY REVIEW CATEGORY
Create PM Maint. Plan Batch Job Processing ... Calibration Recording Sheet
Equipment PM Task List
& Add Gage & Tasklist Search For Maintenance Plans Gage Calibration Report Next/ Gage Calibration Plan’s
Or
To Maint. Plan Within Call Horizon ... Creates Last Calibratied Date Characteristic Target Value(s)
General PM Task List
(Single Cycle) Inspection Lots & PM Orders Recording Sheet
IA01 / IA05 Gage Calb. IP41 / IP02 Gage Calb. IP10 / IP30 Batch Job ZQGAGEREP Super/ Wage
ZQGAGERECSHT Inspector
REVIEW CATEGORY REVIEW CATEGORY REVIEW CATEGORY REVIEW CATEGORY
REVIEW CATEGORY
Create QE
(MIC) Master
Inspection Characteristic
QS21 QM Master Create Sampling Procedure

REVIEW CATEGORY For Gage PM Calibration
QDV1 QM Master
REVIEW CATEGORY
Create
Inspection Method
Create Quality Work Center
QS31 QM Master For Gage Calibration
REVIEW CATEGORY
CRQ1 QM Master
REVIEW CATEGORY

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Gage Calibration Overview
• Plant Maintenance Module

– Manage master data
– Monitor maintenance cycles
– Calibrate
• Quality Management Module

– Inspection characteristics
– Inspection lots
– Results recording
– Usage decision

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Calibration Planning & Processing
PM
PM PM
Equipment Master
Maintenance Plan Equipment Task List
(Gage)
PM QM
Scheduling Inspection Characteristics
PM
Maintenance Order
QM QM
QM
Results Usage
Inspection Lot
Recording Decision

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Master Data
Gage Equipment Master

Gage Task List
Gage Maintenance Plan

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Functions of Equipment Master
(IE01)
• Contains link to Material Master (PRT) via the
Construction Type field.
• Used to track Equipment (Gage)
• Keep record of calibration tasks
• Report and evaluate calibrations over time

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IE01 - Create Equip Master for Gage
• Equipment number will be

created by SAP system
• Valid On:
Earliest date that the gage
can be used
• Equipment category for
Gages is „G‟
Equipment Master General Data (IE01)
1) Equipment number
assigned by SAP system
2) Description describes the
gage function/size
3) Long Text- allows are a
more complete
description of gage
function/size
4) Object type- Catalog
entry that best describes
type of gage
5) Size/dimension- enter the
size range for gage
6) Start-up date- date to start
plan
7) Manufacturer data-
optional information that
describes gage

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Equipment Master Location (IE01)
1) MaintPlant Physical
Plant where gage is
assigned
2) Room- Department
where gage is assigned
3) Work Center- machine
where the gage is
located for production
use
5
4) Sort field- Location
where the gage is
stored.
Cabinet/Draw/Compart
ment, etc.
5) Plant Section – major
building complex
(DSS, FDRY, PEC,
SPO & WAS) – Not
used at JDDMW
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Equipment Master Organization (IE01)
1) Business Area-
Appropriate division in
Deere
2) Cost Center- Department
that is responsible for
Gage Calibration
3) Planning Plant- Plant
responsible for the
calibration of Gage
4) Planner Group- GAU
Planner group that is
responsible for Gage
Calibration
5) Main WorkCtr- Main
Work Center is area
Calibration

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Equipment Master Structure (IE01)
1. Funct. Location-
Physical location in
plant.
2. TechIdenNo- Equals
the legacy gage
number included
from Data Loads
with plant prefix Z
(i.e. NX01-
X75010002)
3. ConstType- Link to
the SAP Material
Master of gage

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Equipment Master PRT Data (IE01)
1) Task List Usage

Set to 009 to
make available
to use on all task
list types

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Equipment Numbers and Maintenance Task list (IA01)
IE01 - PM IA01 - PM
Equipment Master Equipment Task List
(Gage) (characteristics to check)
IP41 - PM
Maintenance Plan
(calibration plan)
IE01- Create Equipment Master

+
IA01- Create Equipment Task List
+
IP41- Create PM Maintenance Plan
Gage Calibration Plan
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Function of Equipment (gage calibration) Task List (IA01)
• Describes the steps (operations) for the calibration

• Inspection characteristics are assigned to the
operation
• Inspection method can be assigned
• Inspection sampling procedure can be assigned.

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Maintenance Task List Structure (IA01)
Group: 12345
Equipment Task List Header:
• Material assignment
• Usage
Task list header
• Status
Operation
• Validity
Operation:
• Inspection Points
Inspection Char. • Control Key
Sampling Procedure • Description
Inspection Method
Inspection Characteristic:
Operation
• Inspection Method
• Sampling Procedure

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Maintenance Task List Header (IA01)

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Maintenance Task List Operation Overview (IA01)
• Work Ctr- Assign the

QM Work Center
Calibration
• CTRL- Control Key; set
to QM05 for Gage
Calibration
• Insp Char- Use to create
Inspection
Characteristics (at bottom
of screen)

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Maintenance Task List Characteristic Overview (IA01)
Quantitative
Inspection
Characteristic
Qualitative
Inspection
Characteristic

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Inspection Characteristics (IA01)
• What do you inspect?

• Describe Inspection criteria
• Used for Planning Inspections
• Store Inspection specifications
• May be Qualitative (pass/fail) or
Quantitative

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Characteristic Overview (IA01)
 Inspection characteristic on a Task List, select the Pre-set Indicator for the type
of inspection characteristic.
- Quantitative = D020
- Qualitative = D010
 Setting preset indicator sets defaults in the Control Indicator screens for the
characteristic. These can be changed if necessary.
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Control Indicators – Quantitative (IA01)
The inspection characteristic

Preset-indicator type
(Quantitative or Qualitative)
determines what information is
displayed.

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Control Indicators – Qualitative (IA01)
The inspection characteristic
Preset-indicator type (Quantitative
or Qualitative) determines what
information is displayed.

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Quantitative Inspection Characteristic (IA01)
• Define Upper/Lower & Target specifications
• Assign sampling procedure
• SPC characteristic
• Summarized or single results recording
• Required/Optional
• Assign test equipment
• Track changes

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Quantitative Data (IA01)

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Sample & SPC (IA01)
The Control indicator for SPC was set, the Sample tab will require
selection of SPC criterion. For gage calibrations, choose: 410 - Task
list char./equipment, funct.loctn.
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Gage Calibration Maintenance Plan
• Calibration Cycle Frequency

• Start Date
• Call Horizon
• Gages to be Planned
• Task list for Gage assigned to Plan

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Maintenance Plan (IP41)
• Cycle text = describe the cycle e.g. Annual

calibration Dec (calibration is planned
once/year in December)
• Cycle = a number
• Unit = period In the example, calibrations are
1/yr
• Equipment: the Gage that will be assigned to
this Calibration plan
When you add the equipment, information
from the equipment master is brought into the
screen. Plant, Work center, planner group
• Priority: A value must be selected to help
define which gage(s) should be calibrated first
• Order type: MUST be AGM5 and
MaintActivityType MUST be M19
• Task List: Select Task List with binocular icon

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Gage Calibration Processing
Call for Gage Calibration

Record Calibration Results
Reporting
Gage Usage Decision

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Calibration Process
• Batch job Scheduled to run weekly

• Generate PM Order and Inspection Lot for each
Gage due for calibration
• Calibration checked and results recorded
• Usage Decision Made

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Inspection Lot
• An inspection lot is a request to a plant to carry out a quality
inspection, in this case Calibration check on a Gage
• An inspection lot is created for a Gage, plant and inspection
lot origin (source)
• Inspection lots are created automatically in the John Deere
system
• The creation of Calibration inspection lots are triggered by
release of a Gage Calibration Maintenance order
Gage Calibration due
Event Quality Inspection

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Scenario – Suspect Gage Out of Calibration
• Run Report of Last/Next Calibration dates

• Create a Call for Calibration manually

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/DEEREAG/QMGAGEREP

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Manual Call for Calibration (IP10)
• Is an Exception process
• Used to Call for a Gage to be calibrated outside
of plan
Examples:
– Dropped the Gage
– Gage not repeating
– Indicator is sticking
• Will be used in class to begin the Calibration
cycle

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Scheduling a Manual Call of Gage
(IP10)
Date will automatically

be entered when the
Manual Call is selected
Manual Call of
Gage will be
created when
the transaction
is SAVED
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Calibration Schedule proposed (IP10)
• The Calibration schedule is initially proposed. Nothing will happen until the plan is
saved.
• When saved: A Maintenance Order will be created and released. (The Equipment
Task list will be copied to the maintenance order.)
• When the PM Order is released, an Inspection Lot is created. Reminder: an

Inspection Lot is a request to inspect something.
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Results Recording – Quality Inspection (QE53)
The quality
inspection takes place
and results must be
recorded for
inspection
characteristics.
During results recording, the user has access to

histograms or control charts.

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Results Recording Worklist for Gages (QE53)
 The Work list for Gages is hierarchical

• Expand one Gage by level or all of them.
• The 3rd level is the Gage master where you will record results
 The Work list displays the PM Order number and Inspection characteristics
assigned to the Equipment Task List
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Results Recording: Characteristics Overview (QE53)
 Results are recorded in Result Column and valuated when Entered

 Specifications Column - contains the Lower & Upper limits

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Usage Decision (QA11)
A usage decision accepts or rejects the inspection lot.
If the lot is accepted, the

Gage can be returned to Accept
Production.
If the lot is rejected,

follow-up actions can be
triggered and the Gage Reject
can be scrapped or sent
for repair.
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Usage Decision: Characteristic Overview (QA11)
Usage Decision is made by

selecting a Code (Accept or
Reject) from the pull down
list.
Use the text field to enter

the reaction plan and
results if a gage fails
calibration.

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Status Change for Object (QA11)
 When SAVING the usage decision, a popup window will appear

asking you to confirm that the Gage is “ready for use”. If you
click the box marked Change, the status will be set to “Not ready
for use”
 Click Green Check mark to continue
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PM Overview

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Process Review

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The topics presented in this course include:

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• Functional location should represent the work team or

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• Functional locations can be used to do cost

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• Preventative Maintenance or Repair type orders

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• BOMs are a list of the components (spare parts)

• Skilled trades group that carry out maintenance work

General Create and View

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 Why do we create work orders?

 Examples of when you might create a work order

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Creating Easy Entry WO

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Select Equipment or Functional Location Creating Easy Entry WO

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Step #3 – Select Order Category Creating Easy Entry WO

2. Each radio button is

Order Type Planned /

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Creating Easy Entry WO

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Step #4 – Selections from 4 menus

Menu #4: List of

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Step #5 – Add WO description; Review; Save Creating Easy Entry WO

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More on a Functional Locations

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It can represent a department

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It can represent a building

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Work Order Status

REL Released Labor & Materials can be charged

PCNF Partially Confirmed Labor Charged; work remaining

CNF Finally Confirmed Labor Charged; all work complete

TECO Technically Complete Work Order is complete

CLSD Closed Work Order closed by batch job if

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IW39 – Example #1:

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List of open work orders for equipment

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IW39 – Example #2:

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 Work Order Types

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Work Order Cycle

Find Work Order Repair Parts and/or Services Needed

Assign Work Order