PLANT MAINTENANCE

1. What do you mean by Full service and Limited service in the service cycle definition
form?
Ans:
Full Service: It denotes the complete maintenance activity of the machine, including the
assembly and disassembly of gear box etc.
Limited Service: It denotes the partial maintenance activity of the machine eg: Limited
service facilities like greasing, cleaning etc.
2. How are the OT1 and OT2 Rate calculated?
Ans:
The system calculated the OT1 and OT2 rate based on the default rate defined. The OT1
is calculated as twice that of the default rate and OT2 is calculated as thrice that of the
default rate.
3. What is the difference between the machines defined under In house maintenance tab
and the Warranty/AMC tab?
Ans:
Those machines that are defined as In house includes activities that covers the
replacement of a part, use of one or more consumables, a maintenance task (defined in
the Master above) or any other resource.
4. How is the daily use in hours calculated?
Ans:
The daily use in hours depends on the shifts selected that are applicable for that
particular machine.
5. Should the counter value be updated on a day to day basis?
Ans:
In order to keep track of the exact nature and time of occurrence of a problem, the user is
required to update the counter value on a day to day basis.
6. When a machine is defined under AMC/Warranty, how do we define the warranty with?
Ans:
The AMC/ Warranty with displays the names of the vendors that are defined in the vendor
master. In case the user need to define a new party with which an AMC is attached, the
user has to first define them in the Vendor master form.
7. Can a machine be under Warranty with two different vendors for the same time period?
Ans:
The system permits to define a machine under warranty with two different vendors for the
same time period.
8. A machine defined under Warranty can it not be defined under In house maintenance?
Ans:
NO. Any machine defined under in house cannot be defined under AMC/Warranty.

9. What does the resource type Part Replacement denote?

Ans:
Machines defined under in-house need to have spare parts and all other accessories to
rectify the machine in case of any problem. All these spare parts and accessories are to
be defined in the item master as Stores and Spares item.
10. What is a preventive maintenance and what is breakdown maintenance?
Ans:
Preventive Maintenance refers to the pro-active, periodic overhaul of various capital
equipment to ensure that they are in good condition. Breakdown Maintenance is triggered
by an emergency caused due to abrupt lack of functioning or unsatisfactory functioning in
capital equipment.
11. What is the system procedure to perform a preventive maintenance activity?
Ans:
Step1: The problem faced with the machine is to be recorded in the Record
machinery problem form

Step2: The user needs to generate a preventive maintenance work order for that
particular machine.
Step3: Once the maintenance activity is performed in the machine, the user is supposed
to go to the record machinery problem and complete the handling details of the
machine.
Step4: once this activity is done, the user is required to close the preventive
maintenance work order, this is done by providing the cost details in the Log
maintenance done screen.
12. What is the system procedure to perform breakdown maintenance?
Ans:
Step1: In case of a breakdown in a machine, the user need to first record the
details in the Record Machinery downtime screen.
Step2: Any breakdown in machine is to be attended on an emergency basis, with this in
mind, Orion lite is designed to generate a breakdown order automatically as soon
as the details are entered.
Step3: Once the machine is repaired and brought back to normal, the details of the
breakdown time is to be recorded.
Step4: The user is then required to close the order by providing the cost details in the
Log maintenance done screen.
13. How is the Problem ID mapped?
Ans:
In the Record Machinery problem screen, the problem recorded in the problem field is
assigned automatically with an auto increment Problem ID. Different problem is assigned
a different Problem ID. Say for example, Problem A is assigned a problem ID 1, and
Problem B is assigned a Problem ID 2. Now suppose the same problem A happens again
with the machine, the Problem ID - 1, could be just mapped. This is done to keep track of
how many times the same problem happens with the machine.