The Maintenance Plans page is used to define, assign, and manage recurring preventive maintenance requirements for Fabritec workstations.

A maintenance plan tells Fabritec:

Which workstations require the service

What type of usage or time triggers the service

When the maintenance becomes due

When the maintenance team should receive an early warning

How much downtime is expected

How the activity is expected to affect production

Which checklist should be included in generated preventive orders

Which parts are expected to be required during the maintenance activity

The expected quantity and estimated unit cost of those parts

Where each workstation starts its service cycle

Instead of manually calculating service dates and equipment usage through spreadsheets, Fabritec compares each workstation’s current meter with its own service baseline.

This allows maintenance teams to understand:

How much of the service interval has been consumed

Which plans are approaching their warning point

Which plans are already due

Which preventive orders have been generated

When usage-based maintenance is expected to become due

When each workstation was last serviced

How maintenance completion affects the next service cycle

Which parts should be prepared before preventive maintenance begins

The expected parts cost of planned preventive maintenance

One maintenance plan can be assigned to several workstations.

However, every selected workstation keeps its own:

Last Service Date

Usage-hours baseline

Usage-items baseline

Current meter

Consumed usage

Due percentage

Maintenance forecast

Preventive orders

Maintenance history

This means that workstations sharing the same plan can become due at different times.

📍 Where to Find Maintenance Plans

Navigate to:

Maintenance → Plans

The Maintenance menu also provides access to:

Workstations

Orders

Parts cost analytics

Planning Calendar

The information and actions available depend on the logged-in user’s maintenance permissions.

Users normally require permission to view maintenance plans.

Creating, editing, activating, deactivating, or otherwise managing plans requires the appropriate maintenance-management permission.

Maintenance Plans Page

The Maintenance Plans page displays the preventive maintenance plans configured for the organization.

The page provides access to:

Maintenance plan register

New maintenance plan creation

Column filters

Excel Export

PDF Export

Refresh

Clear Filter

Columns

Reset Cache

Pagination

The register allows maintenance managers to compare plan configuration across multiple workstations.

Maintenance Plan Register

The register can display information such as:

Plan Name

Workstations

Number of Workstations

Trigger Type

Interval Value

Warn At %

Estimated Downtime

Default Production Impact

Status

Additional information may be available through the Columns menu or when opening the plan.

Plan Name

Displays the name used to identify the maintenance plan.

Examples include:

CNC Plasma Cutting – 500-Hour Service

Automatic Welding Machine – Monthly Inspection

Angle Bending Machine – 10,000-Item Tooling Check

Annual Electrical Safety Inspection

Weekly Cleaning and Lubrication

Use a clear name that identifies:

The equipment or workstation type

The maintenance activity

The service trigger or frequency

Avoid general names such as:

Maintenance

Use a more specific name such as:

CNC Plasma Cutting – 500-Hour Lubrication and Inspection

A clear name makes the plan easier to identify in:

Maintenance Workstations

Maintenance Orders

Planning Calendar

Forecasts

Reports

Management reviews

Workstations

Displays the workstations assigned to the maintenance plan.

A plan can be assigned to:

One workstation

Several individual workstations

Several workstations selected together through a workstation group heading

For example, one plan may be assigned to:

Automatic Welding Machine

CNC Plasma Cutting Machine

Cold Formed Machine

Even when several workstations share the same plan, Fabritec evaluates each workstation independently.

Each workstation has its own:

Current usage

Service baseline

Plan Health

Last Service Date

Preventive orders

Next due point

Number of Workstations

Displays how many workstations are currently assigned to the plan.

For example:

Plan	Assigned Workstations
Main	3
Maintest	3
Test	3

This helps users quickly understand the scope of each maintenance plan.

The number represents the selected workstations, not a shared group-level maintenance record.

Trigger Type

Displays the measurement used to determine when the maintenance service becomes due.

The available trigger types are:

Usage Hours

Usage Items

Time Interval

Each trigger uses a different method to calculate service progress.

Interval Value

Displays the full service interval configured for the plan.

Examples include:

500 hours

10,000 items

30 days

7 days

3 items

The interval is the point at which the plan reaches 100% and becomes due.

Warn At %

Displays the percentage at which Fabritec begins treating the plan as approaching its due point.

Examples visible in the maintenance workflow include:

70%

75%

80%

85%

90%

95%

For a 500-hour plan with an 80% warning:

500 × 80% = 400 hours

The plan reaches its warning point after 400 hours since the last service.

This gives the maintenance team time to prepare before the full 500-hour interval is reached.

Estimated Downtime

Displays the expected duration of the maintenance activity.

Examples include:

1 Hour

3 Hours

4 Hours

8 Hours

Estimated Downtime is copied into preventive maintenance orders generated from the plan.

It helps maintenance and production teams prepare for:

Equipment isolation

Technician availability

Tools and spare parts

Production interruption

Alternative workstation capacity

Inspection and testing

Return-to-service checks

Default Production Impact

Displays the expected effect of the maintenance activity on workstation production.

The available impacts are:

No Stop

Reduced Output

Full Stop

For Reduced Output plans, the configured capacity-reduction percentage can also be displayed.

Example:

Reduced Output (65%)

The plan’s default impact is copied into generated preventive orders.

Authorized users can review the order before execution and adjust its impact when the real maintenance activity requires a different production effect.

Status

Displays whether the maintenance plan is currently active.

Visible statuses can include:

Active

Inactive

Active

An Active plan is included in maintenance evaluation.

Fabritec can:

Calculate its current consumption

Display its Plan Health

Forecast its expected due point

Identify it as Due Soon

Identify it as Due

Generate a Requested preventive order at the warning threshold

Inactive

An Inactive plan is not evaluated for future preventive maintenance requirements.

Inactive plans do not continue generating new preventive orders.

Existing maintenance history remains available.

Use deactivation when:

The maintenance rule is temporarily suspended

The workstation is no longer using that service process

The plan is being replaced

Historical plan information must be preserved

How Maintenance Plans Work

A maintenance plan is a reusable preventive rule.

The plan contains the shared service definition, while every workstation assigned to it keeps an independent service state.

For example, one plan can be assigned to three CNC machines:

Workstation	Baseline Hours	Current Hours	Hours Since Service
CNC Machine 01	2,000	2,450	450
CNC Machine 02	3,000	3,250	250
CNC Machine 03	1,500	1,980	480

If the plan interval is 500 hours:

CNC Machine 01 is at 90%.

CNC Machine 02 is at 50%.

CNC Machine 03 is at 96%.

The machines share the same maintenance definition, but they do not share the same progress or due date.

Multiple Plans on One Workstation

A workstation can have several active maintenance plans.

For example, one CNC Plasma Cutting Machine may have:

A daily safety inspection

A 500-hour lubrication plan

A 10,000-item consumables inspection

A six-month calibration plan

An annual electrical inspection

Each plan keeps its own:

Trigger

Interval

Warning percentage

Last Service Date

Meter baseline

Plan Health

Preventive order

Completion history

Completing the 500-hour lubrication plan does not reset the 10,000-item consumables plan.

Only the completed plan and workstation combination receives a new service baseline.

Workstation Groups

Workstation groups organize the workstation selection list and support bulk selection.

They do not create an inherited or automatically changing plan assignment.

For example:

A user selects all three machines under the Welding Machines group.

Fabritec assigns those three workstation records to the plan.

A fourth machine is later added to the group.

The fourth machine is not automatically added to the existing plan.

The plan must be edited when the new workstation also requires the service.

Similarly, removing a workstation from a group does not automatically remove it from an existing maintenance plan.

Creating a New Maintenance Plan

To create a maintenance plan:

Navigate to Maintenance → Plans.

Click New maintenance plan.

Enter the Plan Name.

Select one or more Workstations.

Select the Trigger Type.

Enter the Interval Value.

Select the Warn At % value.

Enter the Estimated Downtime.

Select the Default Production Impact.

10.

Enter the capacity-reduction percentage when Reduced Output is selected.

11.

Add a Description when required.

12.

Select the Default Priority when available.

13.

Configure the Service Baseline.

14.

Review the baseline for every workstation.

15.

Add the Checklist Template when required.

16.

Add the Planned Parts expected for the maintenance activity.

17.

Enter the planned quantity, unit, and pricing information for each part where available.

18.

Review any parts with missing prices.

19.

Click Save.

Maintenance Plan Fields

Plan Name

Required field

Enter a clear and unique name for the maintenance plan.

The name should help users understand the plan without opening it.

Recommended format:

Workstation or Equipment Type – Service – Trigger

Examples:

CNC Plasma Cutting – 500-Hour Service

Automatic Welding Machine – Monthly Inspection

Galvanizing Bath – 7-Day Safety Check

Cold Formed Machine – 10,000-Item Tooling Inspection

Workstations

Required field

Select one or more workstations covered by the plan.

The picker can display workstation-group headings to simplify bulk selection.

Selecting a group heading selects the currently listed workstations in that group.

Future group changes do not automatically update the plan.

Before saving, confirm that every selected workstation:

Exists and is active

Requires the same maintenance activity

Uses the selected trigger appropriately

Has a valid service history or starting date

Can be measured using the selected usage meter when applicable

Trigger Type

The Trigger Type determines how Fabritec measures progress toward the next service.

Available options include:

Usage Hours

Usage Items

Time Interval

Usage Hours

Select Usage Hours when maintenance becomes due after the workstation has operated for a defined number of hours.

Examples include:

Lubrication every 250 hours

Filter replacement every 500 hours

Motor inspection every 1,000 hours

Major service every 2,000 hours

Fabritec calculates:

Current Cumulative Hours − Baseline Hours

The cumulative usage-hours meter comes from qualifying production records linked to the workstation.

Recorded operation duration contributes to the meter.

Usage Items

Select Usage Items when maintenance becomes due after the workstation has processed a defined quantity.

Examples include:

Inspect tooling every 5,000 items

Replace consumables every 10,000 items

Inspect clamps every 2,500 production units

Service forming tools after 20,000 items

Fabritec calculates:

Current Cumulative Items − Baseline Items

The cumulative usage-items meter comes from non-negative production quantities recorded against the workstation.

Time Interval

Select Time Interval when maintenance becomes due after a defined number of elapsed days.

Examples include:

Inspection every 7 days

Service every 30 days

Calibration every 90 days

Annual safety inspection

Fabritec calculates elapsed days from the workstation’s Last Service Date.

Interval Value

Required field

The Interval Value is the point at which the maintenance plan becomes fully due.

The value is interpreted according to the selected Trigger Type.

Examples include:

Trigger Type	Interval Value	Meaning
Usage Hours	500	Due after 500 operating hours
Usage Items	10,000	Due after 10,000 processed items
Time Interval	30	Due after 30 elapsed days

The Interval Value must be greater than zero.

Use an interval based on:

Equipment manufacturer recommendations

Service manuals

Operating conditions

Maintenance history

Failure patterns

Safety requirements

Internal maintenance policy

Warn At %

The warning percentage controls when Fabritec begins treating the plan as approaching its due point.

For example:

Interval	Warn At	Warning Point
500 hours	70%	350 hours
500 hours	80%	400 hours
500 hours	90%	450 hours
500 hours	95%	475 hours

A lower warning percentage provides more preparation time.

A higher percentage delays the warning until the workstation is closer to the due point.

Use an earlier warning when the service requires:

Imported spare parts

External technicians

Special tools

Production shutdown approval

Alternative workstation planning

Customer coordination

Estimated Downtime

Required field

Enter the expected duration of the maintenance activity in hours.

Examples include:

0.5 for 30 minutes

1 for one hour

3 for three hours

4.5 for four hours and 30 minutes

8 for one full eight-hour shift

The estimate should include:

Preparation

Equipment isolation

Maintenance work

Part replacement

Inspection

Testing

Restart

Return-to-service checks

Generated preventive orders inherit this estimated duration.

Default Production Impact

Required field

Select how the maintenance activity is expected to affect workstation production.

Available options include:

No Stop

Reduced Output

Full Stop

No Stop

Use No Stop when the maintenance activity can be completed without reducing workstation capacity.

Examples include:

External visual inspection

Documentation review

Non-invasive condition monitoring

Inspection performed without interrupting production

No downtime or capacity-reduction window is created when a No Stop order is executed.

Reduced Output

Use Reduced Output when the workstation remains operational but at reduced capacity.

Examples include:

One machine head is unavailable

The workstation must operate at lower speed

Part of the equipment is isolated

Limited tooling remains available

Enter the applicable reduction percentage.

Example:

Reduced Output (65%)

The percentage should reflect the real expected capacity loss.

It must be greater than 0% and less than 100%.

Use Full Stop when the workstation will be completely unavailable.

Full Stop

Use Full Stop when the workstation cannot operate during the service.

Examples include:

Electrical isolation

Major mechanical repair

Internal inspection

Component replacement

Calibration requiring shutdown

Safety lockout

When the generated maintenance order enters active execution, Full Stop removes the affected workstation’s overlapping production capacity.

Only that workstation is affected.

Description

Use the Description field to explain the purpose and scope of the preventive maintenance plan.

A useful description can include:

Maintenance objective

Main equipment components

Service standard

Required safety controls

Expected inspection points

Testing requirements

Reference to the manufacturer’s manual

Example:

Perform a complete preventive inspection and lubrication service every 500 operating hours. Inspect the drive system, bearings, electrical connections, emergency stops, cooling system, and moving components. Replace worn consumables where required and complete a functional test before returning the workstation to production.

Default Priority

The Default Priority is copied into preventive orders generated from the plan.

Available values can include:

Low

Medium

High

Critical

Routine preventive maintenance is commonly assigned Medium priority.

Use High when missing the maintenance interval creates a significant:

Safety risk

Production risk

Quality risk

Equipment-damage risk

Delivery risk

Critical should normally be reserved for urgent conditions rather than routine planned maintenance.

Checklist Template

The Checklist Template defines the standard execution steps copied into preventive orders generated from the plan.

Enter one clear action per line.

Example:

Confirm production handover

Isolate electrical supply

Inspect lubrication points

Check drive belt condition

Inspect bearings

Check emergency stops

Clean filters

Restore power

Run a functional test

Confirm safe production release

A checklist template helps ensure that the same service is performed consistently across:

Different technicians

Different shifts

Multiple workstations

Repeated maintenance cycles

Keep each checklist step specific and verifiable.

The checklist template supports a maximum number and length of steps according to the system validation rules.

Planned Parts

The Planned Parts section allows you to define the parts expected to be required whenever the preventive maintenance plan is performed.

This allows the maintenance team to prepare required parts before the maintenance activity begins and provides planned cost information that can later be compared with actual parts usage and spending.

A plan can contain one or more planned parts.

For example, a preventive service may require:

Bearings

Filters

Contact tips

Feed rollers

Belts

Sensors

Lubricants

Other maintenance consumables

Each planned part can include:

Part Name

Part Code

Unit

Qty

Estimated Unit Cost

Currency

Notes

Part Name

Required field

Enter the name of the part expected to be required during the maintenance activity.

Examples include:

Contact Tip

Feed Roller

Hydraulic Filter

Drive Belt

Bearing

Sensor Cable

Use a clear and specific name so the maintenance technician can identify the required part correctly.

Part Code

Enter the internal, supplier, or manufacturer reference used to identify the part.

Examples include:

CT-12

BRG-6205

FLT-001

SNS-THC-04

The field can be left blank when no part code is available.

Unit

Required field

Select the unit used to measure the part.

For example:

pcs

Use the same unit consistently when the same part is used across different maintenance plans and orders.

Qty

Required field

Enter the quantity expected to be required for one execution of the maintenance plan.

For example:

Part	Planned Qty
Contact Tip	2
Feed Roller	1
Cleaning Filter	1

The planned quantity represents the expected requirement.

The actual quantity used can later be recorded during Maintenance Order execution.

Estimated Unit Cost

Enter the expected cost of one unit of the planned part.

For example:

Part	Qty	Estimated Unit Cost
Contact Tip	2	15
Feed Roller	1	60
Cleaning Filter	1	25

Use the best available expected price based on information such as:

Recent purchase prices

Supplier quotations

Previous maintenance records

Standard internal pricing

The Estimated Unit Cost represents the planned price.

The actual price can be recorded later when the part is actually consumed or replaced during Maintenance Order execution.

Missing Estimated Cost

The Estimated Unit Cost can be left blank when the expected price is not known.

A blank price is not treated as zero.

For example:

USD 0.00 means the price has been recorded as zero.

A blank value means the price is still unknown.

Fabritec can display a missing-price indicator such as:

1 Price missing

Use this indicator to identify planned parts that still require pricing information.

Missing prices can affect the completeness of planned maintenance cost analysis.

Currency

Required field

Select the currency used for the part price.

For example:

USD ($)

The selected currency defines how the planned part price is recorded and displayed.

Make sure the selected currency matches the value entered in Estimated Unit Cost.

Notes

Use the Notes field to record additional information about the planned part.

Notes can include:

Supplier information

Part specification

Preferred manufacturer

Required size

Alternative approved part

Preparation instructions

Other maintenance-specific requirements

Example:

Prepare one additional contact tip in case excessive wear is found during inspection.

Adding More Parts

Click Add part to add another planned part to the maintenance plan.

Each part should be added separately so Fabritec can maintain its own:

Quantity

Unit

Estimated Unit Cost

Currency

Notes

This also allows individual parts to be compared later against their actual maintenance usage.

Copy Parts from Another Plan

Use Copy parts from plan when another Maintenance Plan already contains a suitable planned-parts list.

This is useful when:

Similar workstations require the same maintenance parts

Several plans use the same service kit

A new plan is based on an existing maintenance procedure

To reuse an existing parts list:

Click Copy parts from plan.

Select the source maintenance plan.

Review the copied parts.

Update quantities, prices, currency, or notes when required.

Add or remove parts as needed.

Always review copied parts before saving the plan.

Different workstations may require different quantities, specifications, or prices even when their maintenance procedures are similar.

How Planned Parts Are Used

Planned Parts describe what the maintenance team expects to require before the maintenance activity is executed.

They provide the planned reference for the related preventive maintenance work.

During Maintenance Order execution, the maintenance team can record what actually happened to each part, including whether it was:

Planned

Consumed

Replaced

Not Used

For parts that are consumed or replaced, the actual quantity and actual unit cost can be recorded in the Maintenance Order.

This creates a clear comparison between:

Planned maintenance parts and cost

and:

Actual maintenance parts and cost

The resulting information can be analyzed through Maintenance → Parts cost analytics.

Service Baseline

The Service Baseline defines the starting point from which Fabritec calculates the next maintenance requirement for each selected workstation.

The section can display:

Default Service Date

Apply Date to All

Workstation

Workstation Group

Last Service Date

Baseline Hours

Baseline Items

Current Meter

Since Service

The service baseline is one of the most important parts of initial maintenance-plan setup.

An incorrect baseline can cause the plan to become due too early or too late.

Default Service Date

The Default Service Date is applied to newly selected workstations.

Enter the actual date on which the equipment was last serviced.

Do not automatically use the plan creation date when a previous service has already occurred.

Example:

Actual last service: July 1

Plan created in Fabritec: July 27

The correct Default Service Date should normally be:

July 1

This allows Fabritec to include the equipment usage accumulated since the real service.

Apply Date to All

Use Apply date to all to assign the Default Service Date to all workstations selected in the plan.

Use this action only when the selected workstations were serviced on the same date.

When workstations have different service histories, review and correct each workstation’s date individually during initial setup.

Workstation Baseline Table

After selecting workstations, the Service Baseline table displays one row for each workstation.

Columns can include:

Workstation

Workstation Group

Last Service Date

Baseline Hours

Baseline Items

Current Meter

Since Service

Last Service Date

Shows the service date currently used as the starting date for that workstation and plan.

During initial setup, the date can be corrected before the plan creates maintenance-order history for that workstation.

After maintenance history exists, completion controls the service date.

Baseline Hours

Shows the workstation’s cumulative usage-hours reading at the service baseline.

Users do not enter this value manually.

Fabritec derives it from qualifying production history at the selected service cutoff.

Example:

Last Service Date: July 1

Cumulative Hours at Service: 3,000

Current Hours: 3,450

Consumed Usage:

3,450 − 3,000 = 450 hours

Baseline Items

Shows the workstation’s cumulative usage-items reading at the service baseline.

Users do not enter this value manually.

Fabritec derives it from production history.

Example:

Baseline Items: 20,000

Current Items: 29,000

Consumed Usage:

29,000 − 20,000 = 9,000 items

Current Meter

Shows the workstation’s latest cumulative usage reading.

Depending on the plan, the meter can represent:

Usage Hours

Usage Items

Current meter information is updated from qualifying production activity.

Since Service

Shows how much usage or time has accumulated since the service baseline.

For Usage Hours:

Current Hours − Baseline Hours

For Usage Items:

Current Items − Baseline Items

For Time Interval:

Current Date − Last Service Date

Initial Baseline Editing Rules

The Service Baseline can be corrected only during initial setup.

A workstation’s service date can be edited while that exact plan and workstation have no maintenance-order history.

After a plan-linked preventive order exists:

The baseline becomes controlled by maintenance history.

Baseline hours are calculated automatically.

Baseline items are calculated automatically.

Manual baseline editing is locked.

Completing the preventive order establishes the next baseline.

This rule protects maintenance history from being manually rewritten after real maintenance work has started.

Review every workstation’s baseline before saving the plan and before the first preventive order is created.

Where Maintenance Meter Data Comes From

Fabritec derives usage meters from workstation production records.

Qualifying records include:

Production Progress

Rework Progress

For each qualifying production record:

Operation duration contributes to Usage Hours.

Non-negative production quantity contributes to Usage Items.

The production record’s operation date and time determine when the usage occurred.

The record creation date does not replace the actual operation time.

Users do not manually update the cumulative maintenance meter.

Production remains the source of truth.

Backdated Production Corrections

Fabritec protects consumed usage when a production record is added or corrected before the service baseline.

For example:

Value	Before Correction
Current Hours	12,420
Baseline Hours	12,000
Consumed Since Service	420

A backdated pre-service correction adds 20 hours.

Fabritec updates:

Value	After Correction
Current Hours	12,440
Baseline Hours	12,020
Consumed Since Service	420

The usage occurred before the service, so it should not be treated as wear accumulated after the service.

When production occurs after the service cutoff, only the current meter changes and consumed usage increases normally.

Due and Warning Calculations

Fabritec calculates the plan percentage according to the selected trigger.

Time Interval Calculation

Calculation:

Consumed Days ÷ Interval Days × 100

Example:

Last Service Date: July 16

Current Date: July 27

Consumed Days: 11

Interval: 7 days

Plan Health:

11 ÷ 7 × 100 = 157.1%

The plan is overdue.

Usage Hours Calculation

Calculation:

Consumed Hours ÷ Interval Hours × 100

Example:

Consumed Hours: 450

Interval: 500 hours

Plan Health:

450 ÷ 500 × 100 = 90%

Usage Items Calculation

Calculation:

Consumed Items ÷ Interval Items × 100

Example:

Consumed Items: 9,000

Interval: 10,000 items

Plan Health:

9,000 ÷ 10,000 × 100 = 90%

Due Soon

A plan becomes Due Soon when:

Plan Health ≥ Warn At %

For example:

Interval: 500 hours

Warn At: 90%

Current Consumption: 450 hours

The plan has reached its warning point.

Due

A plan becomes Due when:

Plan Health ≥ 100%

Plan Health may exceed 100%.

Fabritec displays the full percentage so users can see how overdue the service has become.

Preventive Order Generation

When an active plan and workstation reach the configured warning percentage, Fabritec can create one:

Requested, unscheduled Preventive order
The generated order can inherit:

Workstation

Maintenance Plan

Estimated Downtime

Default Priority

Default Production Impact

Capacity-reduction percentage

Checklist Template

Planned Parts

Planned quantities and pricing information

Due target

Planned Parts provide the expected maintenance requirements before execution begins.

During the Maintenance Order, technicians can update the actual usage outcome, quantity, and pricing information based on what was actually consumed or replaced.

This keeps the original maintenance plan intact while preserving the real parts usage and cost against each individual maintenance order.

Fabritec does not create another active preventive order when one is already open for the same plan and workstation.

When the plan later reaches 100%, the same active order continues to represent the maintenance requirement.

This prevents duplicate preventive orders.

Forecast Versus Order

A maintenance forecast is not the same as a maintenance order.

Forecast

A forecast estimates when a maintenance requirement is expected to become due.

It is used for planning.

It does not mean that maintenance work has been scheduled.

Maintenance Order

A maintenance order represents actual maintenance work that must be reviewed, scheduled, executed, and completed.

Forecasts and orders appear as separate event types in the Planning Calendar.

Maintenance Forecasting

Time Interval Plans

Time Interval plans have a predictable due date based on:

Last Service Date

Interval Value

Example:

Last Service Date: July 1

Interval: 30 days

Expected due date:

July 31

Usage-Based Plans

Usage Hours and Usage Items plans require Fabritec to estimate when the remaining usage will be consumed.

Fabritec reviews recent workstation usage and considers:

Recent working days

Zero-usage working days

Non-working days

More recent usage with greater weight

Remaining usage

Future workstation working days

The forecast is based on recent activity and can change as production usage changes.

When there is no recent usage, Fabritec may indicate that the plan cannot currently be forecast.

A missing forecast does not mean the plan is inactive.

It means there is not enough recent usage to estimate a reliable calendar due date.

Editing a Maintenance Plan

To edit an existing plan:

Navigate to Maintenance → Plans.

Open the required plan.

Review the current configuration.

Update the permitted fields.

Review the assigned workstations.

Review the Service Baseline lock state.

Save the changes.

Changes can affect future:

Plan Health

Warning timing

Due timing

Forecasts

Generated preventive orders

Production-impact defaults

Historical maintenance orders preserve the maintenance information recorded when they were created.

Plan changes should not be used to rewrite completed maintenance history.

Activating and Deactivating Plans

Activating a Plan

Activate a plan when it should be evaluated for preventive maintenance.

Before activation, confirm:

At least one active workstation is selected.

The Trigger Type is correct.

The Interval Value is valid.

The warning percentage is appropriate.

Estimated Downtime is realistic.

Production Impact is correct.

Service Baselines are accurate.

Deactivating a Plan

Deactivate a plan when it should stop generating future preventive requirements.

Use deactivation when:

The equipment is temporarily out of service

The maintenance rule has been replaced

The maintenance activity is no longer applicable

The plan requires review

Historical records must remain available

Deactivation preserves maintenance history.

Deleting a Maintenance Plan

Deletion is intended for plans created in error and without maintenance-order history.

A plan with maintenance-order history should not be deleted because its information supports:

Historical orders

Maintenance reporting

Service traceability

KPI calculations

Audit history

When history exists, deactivate the plan instead.

Complete Example: 500-Hour Preventive Service

Assume the company operates two CNC Plasma Cutting Machines.

Both require lubrication and inspection every 500 operating hours.

Create the plan using:

Field	Value
Plan Name	CNC Plasma Cutting – 500-Hour Preventive Service
Workstations	CNC Plasma Machine 01 and CNC Plasma Machine 02
Trigger Type	Usage Hours
Interval Value	500
Warn At	90%
Estimated Downtime	3 hours
Default Priority	Medium
Default Production Impact	Full Stop
Last Service Date	July 1, 2026

Checklist Template

Confirm production handover

Isolate electrical supply

Inspect torch assembly

Inspect gantry movement

Check lubrication points

Inspect cables and connections

Clean filters

Test emergency stops

Restore power

Complete sample cut

Confirm safe production release

Assume Fabritec derives the following meter information:

Workstation	Baseline Hours	Current Hours	Since Service	Plan Health
CNC Plasma Machine 01	2,000	2,450	450	90%
CNC Plasma Machine 02	3,100	3,300	200	40%

The result is:

Machine 01 reaches the 90% warning point.

Fabritec creates one Requested preventive order for Machine 01.

Machine 02 remains below the warning point.

No order is created for Machine 02.

Both machines continue using the same plan definition.

Each machine keeps its own service baseline and due progress.

After Machine 01’s preventive order is completed:

Its current meter is captured as the new baseline.

Its Plan Health restarts from 0%.

Machine 02 remains at its existing progress.

Machine 02’s baseline is not changed.

Planned Parts

The plan can also include the parts expected to be required during the service.

For example:

Part Name	Part Code	Unit	Qty	Estimated Unit Cost	Currency
Contact Tip	CT-12	pcs	2	15	USD
Feed Roller	FR-01	pcs	1	60	USD
Cleaning Filter	CF-01	pcs	1	25	USD

These values represent the expected parts requirement and planned cost before maintenance begins.

When the preventive Maintenance Order is executed, the technician records the actual outcome for the parts.

For example:

Two Contact Tips may be Consumed.

The Feed Roller may be inspected and marked Not Used.

The Cleaning Filter may be Replaced.

Actual quantities and prices can be recorded where applicable.

This allows Fabritec to compare the planned maintenance parts cost with the actual parts cost after execution.

Complete Example: Usage Items Plan

Assume an Angle Bending Machine requires a tooling inspection every 10,000 processed items.

Configure:

Field	Value
Plan Name	Angle Bending – 10,000-Item Tooling Inspection
Trigger Type	Usage Items
Interval Value	10,000
Warn At	85%
Estimated Downtime	1.5 hours
Default Priority	Medium
Default Production Impact	Reduced Output
Capacity Reduction	40%

The warning point is:

10,000 × 85% = 8,500 items

When the workstation reaches 8,500 items since service:

The plan becomes Due Soon.

Fabritec can create one Requested preventive order.

The order inherits the plan’s Reduced Output impact.

The maintenance planner reviews and schedules the order.

When the workstation reaches 10,000 items:

The plan becomes Due.

The existing open preventive order continues to represent the work.

No duplicate order is created.

Complete Example: Time Interval Plan

Assume a Galvanizing Bath requires inspection every seven days.

Configure:

Field	Value
Plan Name	Galvanizing Bath – 7-Day Inspection
Trigger Type	Time Interval
Interval Value	7
Warn At	75%
Estimated Downtime	4 hours
Default Priority	Medium
Default Production Impact	Full Stop
Last Service Date	July 16, 2026

The warning point is reached after:

7 × 75% = 5.25 days

Fabritec begins treating the plan as approaching due during the configured warning stage.

On July 27:

Days since service: 11

Interval: 7 days

Plan Health: 157.1%

Plan Status: Due

Calculation:

11 ÷ 7 × 100 = 157.1%

The overdue percentage remains visible until the related preventive order is completed.

After completion:

The actual completion date becomes the new Last Service Date.

The applicable workstation and plan baseline is reset.

A new seven-day cycle begins.

The next expected due date is recalculated.

Implementing Maintenance Plans

A practical implementation sequence is:

1. Review Maintainable Workstations

Navigate to:

Production Setup → Workstations

Confirm that every maintainable machine or work area has:

A clear name

A unique code

The correct Production Stage

The correct Workstation Group

A valid Effective Date

Appropriate production tracking

2. Prepare the Maintenance Plan List

Before creating plans, prepare a list containing:

Workstation

Maintenance Activity

Trigger Type

Interval

Warning Point

Estimated Downtime

Production Impact

Priority

Checklist

Planned Parts

Planned Quantities

Estimated Part Prices

Currency

Last Service Date

Use:

Manufacturer manuals

Existing maintenance records

Technician experience

Breakdown history

Safety requirements

For planned parts and pricing, also review:

Previous maintenance orders

Supplier quotations

Recent purchase prices

Recommended service kits

Technician consumption history

3. Create Separate Plans for Separate Frequencies

Do not combine maintenance activities with different triggers into one plan.

For example, create separate plans for:

Weekly cleaning

500-hour lubrication

10,000-item tooling inspection

Annual calibration

Each plan should represent one repeatable maintenance rule.

4. Assign the Correct Workstations

Select individual workstations or use group headings for bulk selection.

Confirm the selected list before saving.

Remember that future workstation-group changes do not update the plan automatically.

5. Select the Correct Trigger

Use:

Usage Hours for operating-time wear

Usage Items for production-cycle or quantity wear

Time Interval for calendar-based maintenance

6. Enter the Service Interval

Use a realistic interval based on technical and operational requirements.

Avoid extending an interval only to reduce the number of maintenance orders.

An unrealistic interval can increase:

Failure risk

Quality problems

Breakdown frequency

Repair cost

Production delay

7. Configure the Warning Point

Choose a warning percentage that gives the maintenance team enough preparation time.

Consider:

Part lead time

Technician availability

Production planning

Shutdown approval

External service requirements

8. Configure Downtime and Impact

Enter realistic Estimated Downtime.

Select:

No Stop

Reduced Output

Full Stop

When using Reduced Output, enter a realistic capacity-reduction percentage.

9. Create the Checklist Template

Add the standard maintenance actions required for consistent execution.

Keep each checklist line:

Clear

Specific

Verifiable

Relevant to the service

10. Add Planned Parts

Add the parts normally required when the maintenance activity is performed.

For each part, review:

Part Name

Part Code

Unit

Qty

Estimated Unit Cost

Currency

Notes

Enter realistic planned quantities based on the normal maintenance procedure.

When pricing is known, enter the Estimated Unit Cost.

When the price is unknown, leave the value blank rather than entering zero.

Review any missing-price indicators before activating the plan.

Use Copy parts from plan when another maintenance plan already contains a suitable parts list, then review the copied quantities and pricing before saving.

11. Establish the Initial Baseline

Enter the actual Last Service Date for each workstation.

Review the derived baseline and current meter information.

Complete this review before the plan generates its first preventive order.

12. Activate the Plan

Activate the plan after confirming:

Workstations

Trigger

Interval

Warning point

Downtime

Impact

Checklist

Baselines

13. Monitor the Plan

Use:

Maintenance → Workstations

Maintenance → Plans

Maintenance → Orders

Maintenance → Planning Calendar

Review:

Due Soon plans

Due plans

Generated preventive orders

Forecasts

Last Service Dates

Workstations without active plans

Permissions

Maintenance Plans are controlled by maintenance permissions.

Relevant permissions include:

View Maintenance Plans — Opens the plan register and displays plan details, service baselines, and forecasts.

Manage Maintenance — Creates, edits, activates, deactivates, and manages maintenance plans.

View Maintenance Orders — Displays preventive orders generated from plans.

View Maintenance KPIs — Displays plan-related maintenance insight and performance information.

Users without management permission may be able to review plans without changing them.

Governance Rules

Every maintenance plan must have a clear name.

At least one active workstation must be selected.

One plan can be assigned to several workstations.

One workstation can have several active plans.

Every plan and workstation combination keeps an independent service baseline.

Workstation groups support bulk selection only.

Future group membership changes do not update plans automatically.

Trigger Type must match the intended maintenance measurement.

Interval Value must be greater than zero.

Warning percentage must be valid.

Estimated Downtime must be greater than zero.

Reduced Output requires a valid capacity-reduction percentage.

Usage meters are derived from production records.

Users do not manually enter cumulative meter values.

The actual Last Service Date should be used during initial setup.

Manual baseline correction is available only before maintenance-order history exists.

After history exists, maintenance completion controls the baseline.

A plan becomes Due Soon at its warning threshold.

A plan becomes Due at 100%.

Plan Health may exceed 100%.

One active preventive order should exist for the same plan and workstation.

Reaching 100% must not create a duplicate order.

Completing one plan must not reset another plan.

Only plan-linked Preventive completion resets a preventive baseline.

Corrective and Inspection orders do not reset plan baselines.

Forecasts are estimates, not scheduled maintenance orders.

Inactive plans are not evaluated for new preventive requirements.

Plans with maintenance history should be deactivated rather than deleted.

Historical orders must remain connected to their original plan information.

A maintenance plan can contain one or more Planned Parts.

Each planned part should have a clear Part Name, Unit, and planned quantity.

Planned parts can include an Estimated Unit Cost and Currency.

A missing part price is not treated as zero.

Planned Parts represent expected maintenance requirements, not confirmed actual usage.

Actual part usage is recorded against the Maintenance Order.

Consumed and Replaced parts can use actual quantity and actual pricing during order execution.

Parts copied from another plan should be reviewed before saving.

Changes to Planned Parts affect future maintenance planning and should not be used to rewrite completed Maintenance Order history.

⭐ Best Practices

Use clear plan names that identify the equipment and service.

Create one plan for each distinct maintenance frequency.

Base intervals on manufacturer recommendations.

Review intervals against real breakdown history.

Use Usage Hours for operating-time wear.

Use Usage Items for cycle or quantity-based wear.

Use Time Interval for calendar-based requirements.

Use warning percentages that allow enough preparation time.

Select an earlier warning when parts have long lead times.

Enter realistic Estimated Downtime.

Include isolation, testing, and restart in the downtime estimate.

Select the correct production impact.

Enter a realistic reduction percentage for Reduced Output.

Use Medium priority for routine planned work.

Reserve Critical priority for genuinely urgent conditions.

Build reusable and verifiable checklist templates.

Use one action per checklist line.

Enter the real Last Service Date.

Review every workstation’s baseline before activation.

Do not assume all workstations in one plan have the same due date.

Do not assume adding a workstation to a group adds it to existing plans.

Review Due Soon plans during maintenance planning meetings.

Review Due plans at the start of every shift.

Schedule preventive work before it becomes overdue.

Complete preventive orders promptly so the next baseline is accurate.

Deactivate obsolete plans instead of deleting historical records.

Review workstations without active plans regularly.

Use Refresh after changing plan configuration.

Use Reset Cache only when Refresh does not update the register.

Add Planned Parts when recurring maintenance normally requires known parts or consumables.

Use clear and consistent Part Names and Part Codes.

Enter realistic planned quantities based on actual maintenance experience.

Enter Estimated Unit Cost when reliable pricing is available.

Leave unknown prices blank instead of entering zero.

Review missing-price indicators before activating the plan.

Keep the selected currency consistent with the entered part price.

Use Copy Parts from Plan for similar maintenance procedures.

Review copied parts before saving because quantities and pricing may differ between workstations.

Compare planned parts with actual maintenance usage to improve future maintenance planning.

Maintenance Plans

Maintenance Plans Page#

Maintenance Plan Register#

Plan Name#

Workstations#

Number of Workstations#

Trigger Type#

Interval Value#

Warn At %#

Estimated Downtime#

Default Production Impact#

Status#

Active#

Inactive#

Page Tools#

New Maintenance Plan#

Column Filters#

Excel Export#

PDF Export#

Refresh#

Clear Filter#

Columns#

Reset Cache#

Pagination#

How Maintenance Plans Work#

Multiple Plans on One Workstation#

Workstation Groups#

Creating a New Maintenance Plan#

Maintenance Plan Fields#

Plan Name#

Workstations#

Trigger Type#

Usage Hours#

Usage Items#

Time Interval#

Interval Value#

Warn At %#

Estimated Downtime#

Default Production Impact#

No Stop#

Reduced Output#

Full Stop#

Description#

Default Priority#

Checklist Template#

Planned Parts#

Part Name#

Part Code#

Unit#

Qty#

Estimated Unit Cost#

Missing Estimated Cost#

Currency#

Notes#

Adding More Parts#

Copy Parts from Another Plan#

How Planned Parts Are Used#

Service Baseline#

Default Service Date#

Apply Date to All#

Workstation Baseline Table#

Last Service Date#

Baseline Hours#

Baseline Items#

Current Meter#

Since Service#

Initial Baseline Editing Rules#

Where Maintenance Meter Data Comes From#

Backdated Production Corrections#

Due and Warning Calculations#

Time Interval Calculation#

Usage Hours Calculation#

Usage Items Calculation#

Due Soon#

Due#

Preventive Order Generation#

Forecast Versus Order#

Forecast#

Maintenance Order#

Maintenance Forecasting#

Maintenance Plans Page

Maintenance Plan Register

Plan Name

Workstations

Number of Workstations

Trigger Type

Interval Value

Warn At %

Estimated Downtime

Default Production Impact

Status

Active

Inactive

Page Tools

New Maintenance Plan

Column Filters

Excel Export

PDF Export

Refresh

Clear Filter

Columns

Reset Cache

Pagination

How Maintenance Plans Work

Multiple Plans on One Workstation

Workstation Groups

Creating a New Maintenance Plan

Maintenance Plan Fields

Plan Name

Workstations

Trigger Type

Usage Hours

Usage Items

Time Interval

Interval Value

Warn At %

Estimated Downtime

Default Production Impact

No Stop

Reduced Output

Full Stop

Description

Default Priority

Checklist Template

Planned Parts

Part Name

Part Code

Unit

Qty

Estimated Unit Cost

Missing Estimated Cost

Currency

Notes

Adding More Parts

Copy Parts from Another Plan

How Planned Parts Are Used

Service Baseline

Default Service Date

Apply Date to All

Workstation Baseline Table

Last Service Date

Baseline Hours

Baseline Items

Current Meter

Since Service

Initial Baseline Editing Rules

Where Maintenance Meter Data Comes From

Backdated Production Corrections

Due and Warning Calculations

Time Interval Calculation

Usage Hours Calculation

Usage Items Calculation

Due Soon

Due

Preventive Order Generation

Forecast Versus Order

Forecast

Maintenance Order

Maintenance Forecasting

Time Interval Plans