Maintenance

Set it up in your plant

Setting up Maintenance in your plant. Maintenance keeps your assets running: breakdowns reported from the floor with a photo, work orders assigned, done and closed with what failed and why, preventive work opened by itself on its dates, spare parts and their cost, and a board that shows where the downtime goes and how long repairs take.

1. Install itIT

   On the plant's OpenCore MES server, in its plant folder: sign in once with a licence token from your account at suites.opencoremes.com, install the suite, then restart OpenCore MES (opencore-mes start, or the service that runs it). Newer versions are said in About; nothing of yours is lost by an update.

   opencore-mes suite login

   opencore-mes suite install maintenance

2. Try it on a test installation firstIT

   Install it on a test or training installation before production. There, load its sample records (Designer → From the suites → Load its sample records): six assets, preventive plans, a season of repaired breakdowns. Walk the Maintenance board and a breakdown from report to close with the people who will use them. Samples never go on production.

3. Prepare People & departmentsAdministrator

   The suite's designs give their roles to the groups engineering (planners and technicians: plans, assigns and does the work), production (reports breakdowns, asks for work, records meters) and quality and it (read). Where your plant has a maintenance group of its own, give it the planner and technician roles in the change instead (next step).

4. Take its designs through a changeDesigner

   Designer → From the suites → Start a change from it. The change holds the asset, work order, preventive plan and part used objects, the seven moves, the two plans (preventive work due, work order overdue) and the four screens with their charts. Change what differs in your plant (asset kinds, failure codes, priorities, the board's charts), run the fitness test, submit; Engineering approves it.

5. Enter your assets and preventive plansEngineering

   Create your assets (id, name, kind, criticality: A when it stops the line, location, line, make, meter, manual and photo) and their preventive plans (what to do, every how many days, the next date). For many at once, import them from Excel (Data → Import / export). Open work from your old system is entered once under the opening policies.

   • Once they are in, remove the opening policies (mnt_*-opening) through a change: from then on an asset's state moves only with the work.
6. Report and repairProduction

   Put the Report a breakdown screen at the lines (or its move on the screens operators already use): the asset, what is wrong, a photo, whether it stopped. Maintenance assigns it, starts it (the asset under maintenance), records the parts used, and completes it with what failed, why, how long the asset was down and the work took: the asset is back in service, the planner closes the work order.

7. Let preventive work open itselfEngineering

   Each active preventive plan opens its work order on its next date, as the plan, and moves the date on by its interval; a work order past its due date asks the planner. Pause a plan to stop it for a while.

8. Read the boardEngineering

   The Maintenance board's charts are drawn from the work orders themselves: where the downtime goes (the few assets that cost the most), breakdowns and the mean time to repair by asset, the failures that matter most. Review them in your weekly maintenance meeting; an asset's page shows its own history and failures.

9. Go liveEngineering

   Train the lines on reporting breakdowns and the technicians on completing work orders with their failure and minutes: the board is only as good as what they enter.

The same guide is in FLAMES once the suite is installed: Designer, From the suites, Set-up guide.