Building an Asset Register: Example

The example discussed below is based on the On Key Demo database, which is distributed with On Key.

Note:

The company is “ABC Brands”, which has three divisions: ABC Facilities, ABC Manufacturing and Packaging, and ABC Mining.
An Asset Type Tree has been configured with functional units, sub assemblies, machines and production lines.
An Asset Tree has been configured for the ABC Manufacturing & Packaging divisions in Port Shepstone and Port St Johns.
The ABC Manufacturing & Packaging division in Port Shepstone wants to use On Key to manage their Assets, which include production lines in the Filling Hall, a pump station in the processing plant, forklift trucks etc.

- Example -

This example focuses on a Squirrel Cage AC Motor in the 4-Speed Drive Unit that is located in the Pump Station.

In this example we use

A “top down” approach to analyse the requirements for the different types of motors.
A “bottom up” approach to configure Asset Type models for Units and Assemblies that are used in a motor, which is a machine.

Analyse the existing infrastructure

The company, ABC Brands, has two types of filling lines and a Pump Station that supplies product to the filling lines at Port Shepstone.

A Filling Line for bottles, which is made up of a Capper, Filler and Labeller.
A Filling Line for milk boxes, which is made up of an Accumulator, Capper, Filler and Packer.
A Pump Station, which is made up of a Coupling, 4-speed Drive Unit and centrifugal Pump.

Drive units are made up of a gearbox and motor.

4-Speed Drive Unit, which has a STX Gearbox and a Squirrel Cage AC Motor
5-Speed Drive Unit, which has a STY Gearbox and a Slipring AC Motor

Motors are made up of a casing, which comprises a bearing and a motor, and can be AC Motors or DC Motors.

AC Motors are Squirrel Cage AC Motors, Slipring AC Motors and Vibrating AC Motors.
DC Motors.

Identify the Assets for which Asset Types are needed

ABC Manufacturing & Packaging at Port Shepstone has a filling hall, material movement equipment, a processing plant and services; each of which is set up as a folder. The Filling Hall contains Filling Lines for bottles and boxes, which have been configured, and the Processing Plant has a Pump Station, which has not been configured, that supplies product to the Filling Lines.
The Pump Station contains a 4-speed Drive Unit, a Coupling and a Centrifugal Pump. The Pump Station must be maintained and will be configured as an Asset in the Asset Tree so an Asset Type for a pump station is configured in the Asset Type Tree.
The 4-speed Drive Unit, a Coupling and a Centrifugal Pump are not maintained .

Identify the Sub Assembly Building Blocks

Sub assembly building blocks are combinations of functional unit Asset Type models and Components.
A Drive Unit, which consists of a Gearbox and a Motor, is a sub assembly and will be configured as an Asset Type in the Asset Type Tree.
Sub assemblies are grouped in a “Sub-Assemblies” folder in the Asset Type Tree.

Identify the Functional Unit Building Blocks

Functional unit building blocks are parts of an Asset that will be used more than once to build sub assemblies or machines.

In our example gearboxes, motors and pumps are identified as functional units because they are used to build a sub assembly for a Drive Unit.

In a manufacturing and production environment, motors, gearboxes and pumps are used for many Assets.

Each of these items or parts is configured as an Asset Type that may need to be repaired or replaced and represents a building block or functional unit in the Asset Type Tree.

A gearbox has a housing component that is made up of a bearing, collar, gear and shaft.
A motor has a terminal box component and a casing component, which is made up of a bearing and a rotor.
A pump has a casing component that is made up of bearings, electrical components and a shaft.

An item or part of an Asset that is only used once can be configured as an Asset Type or Component where they occur in the Asset Type model.

Functional units are grouped in a “Functional Units” folder in the Asset Type Tree.