MAPCON allows up to 99 levels in a hierarchy. The number of levels allowed in a hierarchy can be entered on the Set Equipment Software Switches screen during system initialization. The default level is five. It is suggested that only up to five be used, unless dictated otherwise.
Prior to entering data, the following Validation Files need to be set up so that Equipment data will be complete:
Equipment Keywords / Specification Titles
Categorize Equipment with Keywords; Use Specifications to list detailed equipment information. Optionally print Equipment Specification data on work orders.
Use a cost center to keep track of all work order charges against the equipment.
Meter/Gauge Units of Measure
Keep track of Meter or Gauge readings. Trigger PM work orders based on readings.
Use Ratings to indicate the importance of equipment (also used in calculating work order scheduling).
Indicate where to find equipment. Also used for writing work orders to an area rather than an asset.
Categorize locations for selecting and sorting on reports.
Use Location Ratings to indicate the importance of an area.
Safety Job Steps
Create predefined steps for workers to follow in safety procedures, or build a checklist for inspections.
Create Safety Procedures to be attached to equipment, such as Lock Out/Tag Out or Confined Spaces.
Vendors and Manufacturers
Indicate who the equipment was purchased from, and who built it.
In addition, there are handy Equipment Utilities to track or view additional Equipment data:
Equipment Failure Analysis
View Completed Work Orders
View Open Work Orders
Asset Administration Menu
Asset Administration Menu
Maintain Equipment Keywords - Setup equipment keywords. Keywords should represent a generic class of equipment. For example, Motor, Compressor, etc. Assign multiple characteristics to each equipment keyword, such as MOTOR-AC, or MOTOR-DC. The most important characteristics should be listed first for proper grouping and sorting on reports.
Maintain Location Keywords - Setup location keywords. Keywords should represent a generic class of locations. For example, Classroom, Hallway, or General Production. Assign multiple characteristics to each location keyword such as length, width, exits, etc. The most important characteristics should be listed first for proper grouping and sorting on reports.
Maintain Property Keywords - Setup property keywords. Keywords should represent a generic class of property. For example, Classroom, Hallway, or General Production. Assign multiple characteristics to each location such as length, width, exits, etc. The most important characteristics should be listed first for proper grouping and sorting on reports.
Maintain Equipment Meter/Gauge Units of Measure - Define allowed units of measure.
Safety Menu - Setup safety procedures and instructions.
Equipment Administration Report Menu - Reports showing lists of data entered.
Equipment Utilities Menu - Handy utilities to help keep Mapcon data linked correctly.
Maintain Calibration Types - Setup calibration Types.
Maintain Calibration Codes - Setup calibration Codes.
Equipment Utilites Menu
Rebuild Equipment Hierarchy - Use this utility after removing Equipment from the system.
Reset Equipment Hierarchical Costs - Use this feature to clear the costs for any equipment hierarchy.
Rebuild Completed Work Order Lists - Use this utility to update or refresh the view window for completed work orders after deleteing equipment from the system.
Procedures Missing Equipment Report - Use this report to help find Equipment that has a PM Procedure, but the PM Procedure does not have the equipment number. If any are found, run the Rebuild Procedure/Equipment Links option on this menu.
Equipment Missing Procedures Report - Use this report to help find PM Procedures that have an Equipment number, but the Equipment does not have the PM Procedure number. If any are found, run the Rebuild Procedure/Equpiment Links option on this menu.
Rebuild Procedure/Equipment Links - Run this if any records are found using either of the previous two reporting options on this menu.
Equipment can be placed into a Hierarchy. Hierarchy is defined by Webster as a grouping ordered by rank and class. The purpose of an Equipment Hierarchy is to simplify the reporting of maintenance costs. Costs applied to a lower level in a hierarchy will automatically "roll up" (i.e. be applied) to higher levels in the hierarchy. A hierarchy is not meant to include every piece of Equipment in the plant. It should be used only where a roll up of costs is desirable. There can be several small hierarchies that are not connected.
An element placed in the hierarchy does not have to be a real piece of Equipment. For example, several small hierarchies could be created and attached to an Equipment entry labeled Plant. In that case, one could always display the Plant Equipment record and see the accumulated cost of all the smaller hierarchies attached to it.
Work orders can be written against Equipment at any hierarchical level.
When building a hierarchy, enter the piece of Equipment that has the highest level first. Then enter the piece(s) of equipment for the next level and attach them to the Equipment at the higher level. Repeat the process for as many levels as desired (up to the maximum number).
For example, if a pump on a main assembly line is the highest level, the numbering system could be like the one shown below:
Description Equipment #
Pump #1 on Main Assembly Line 10000
Gear Reducer on Pump #1 10005
Motor on #1's Gear Reducer 10010
Three Equipment records are established for this example:
EQP # Next Level
Record # 1 10000
Record # 2 10005 10000
Record # 3 10010 10005
As Equipment data is being entered, only the numbers of the piece of Equipment being entered and the piece of Equipment immediately above it in the hierarchy are displayed. The system constructs the ties to the other levels in the hierarchy automatically.
WARNING: Equipment should be placed in a hierarchy prior to any Work Orders being written against the Equipment. If the hierarchy is set up at a later date, costs associated with Work Orders written prior to hierarchy setup will not have been rolled up. This will cause Equipment at higher levels in the hierarchy to have inaccurate hierarchical costs.