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Inventory Control / Preventive Maintenance
For
Water/Wastewater Treatment Facilities
Operations Manual
TrailBlazer Software Systems
1115 B Millersville Ave
Howards Grove, WI 53083-1441
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
Inventory Control / Preventive Maintenance
For
Water/Wastewater Treatment Facilities
1. TrailBlazer Software License....................................1
2. Copyright.......................................................1
3. Other Restrictions..............................................1
4. Warranty........................................................1
5. Liability Of TrailBlazer Software And/Or Its Authors............1
6. Whats New!!.....................................................2
7. System Requirements.............................................4
8. System Configuration............................................4
9. Files Needed For This Program To Operate Properly...............5
10. Files Produced By The Software..................................6
11. Batch Files Included With The Software..........................6
12. A Little History And What This Software Can Do For You..........7
13. Manufacturer & Vendors Database.................................7
14. Manufacturer & Vendors Database Helpful Hints...................8
15. Label Maker And Inventory Transactions.........................12
16. Label Printout Helpful Hints...................................12
17. Equipment Record Database......................................13
18. Equipment Database Helpful Hints...............................13
19. Equipment Database Helpful Hints Cont..........................14
20. Equipment Database Helpful hints Screen #2.....................14
21. Equipment Database Helpful Hints Equipment History Log.........15
22. Scheduled Maintenance Tasks Database...........................16
23. Scheduled Maintenance Tasks Database Helpful Hints.............17
24. Scheduled Maintenance Tasks Helpful Hints Cont.................18
25. Scheduled Maintenance Tasks Helpful Hints Screen #2............18
26. Unscheduled Maintenance Tasks Database.........................19
27. Unscheduled Maintenance Tasks Helpful Hints....................19
28. Unscheduled Maintenance Tasks Helpful Hints Cont...............20
29. Unscheduled Maintenance Tasks Helpful Hints Screen #2..........20
30. Unscheduled Maintenance Helpful Hints Updating Work Orders.....21
31. Work Orders And Task Listing For Scheduled Maintenance.........22
32. Work Orders Helpful Hints......................................22
33. Work Orders Helpful Hints Screen #2............................23
34. Valve Database.................................................24
35. Valve Database Helpful Hints...................................24
36. Valve Database Helpful Hints Cont..............................25
37. Valve Database Helpful Hints Screen #2.........................25
38. Valve Database Helpful Hints Valve History Log.................26
39. Disk Space Requirements........................................27
40. General Configuration..........................................27
41. General Configuration Helpful Hints............................28
42. Color Configuration Menu.......................................29
43. Installing On-line Help........................................30
44. Other Notes....................................................31
45. Registration...................................................31
46. Support........................................................31
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
Inventory Control / Preventive Maintenance
For
Water/Wastewater Treatment Facilities
**** PLEASE BE SURE TO READ THE FOLLOWING CAREFULLY ****
TrailBlazer SOFTWARE LICENSE
~~~~~~~~~~~~~~~~~~~~~~~~~~~~
*** NOTE *** These three paragraphs are for REGISTERED VERSIONS ***
~~~~~~~~~~~~~~~~~~~
1. GRANT OF LICENSE. TrailBlazer Software Systems and its Authors
grant to you the right to use one copy of the enclosed TrailBlazer
SOFTWARE program on a single terminal connected to a single computer.
You may not network the SOFTWARE or otherwise use it on more than one
computer or computer terminal at the same time.
2. COPYRIGHT. The SOFTWARE is owned by TrailBlazer Software Systems
and/or its Authors and is protected by United States copyright laws
and international treaty provisions. Therefore, you must treat the
SOFTWARE like any other copyrighted material except that you may
either (a) make one copy of the SOFTWARE solely for backup or archival
purposes, or (b) transfer the SOFTWARE to a single hard disk provided
you keep the original solely for backup or archival purposes.
3. OTHER RESTRICTIONS. You may not rent or lease the SOFTWARE, but
you may transfer the SOFTWARE and accompanying written materials on a
permanent basis provided you retain no copies and the recipient
agrees to these terms set forth. You may not reverse engineer,
decompile, or disassemble the SOFTWARE. If the SOFTWARE is an update,
any transfer must include the update and all prior versions. The new
user must REGISTER his/her name with TrailBlazer Software Systems
and/or its Authors to ensure future updates and/or changes. New users
must send their name, address, city, state, zip and phone number to
the enclosed addresses.
NO OTHER WARRANTIES TO ALL USERS
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
TrailBlazer Software Systems and/or its Authors disclaims all other
warranties, whether express or implied, including but not limited to
implied warranties of merchantability and fitness for a particular
purpose, with respect to the SOFTWARE or the accompanying written
materials.
NO LIABILITY FOR CONSEQUENTIAL DAMAGES
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
TrailBlazer Software Systems or its Authors shall have no liability or
responsibility to a registered user or any other person or entity with
respect to any liability, loss, or damage caused by or alleged to be
caused directly or indirectly by SOFTWARE sold, licensed or registered
by TrailBlazer Software Systems or its Authors, including, but not
limited to, any interruption of service, loss of business or
anticipatory profits or consequential damages resulting from the use
of this SOFTWARE. It is the responsibility solely of the user to
determine the suitability of this SOFTWARE for any purpose and in any
case TrailBlazer Software Systems or its Authors liability to
REGISTERED USERS for any claim regarding this SOFTWARE product is
limited to its registration price.
1
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
Inventory Control / Preventive Maintenance
For
Water/Wastewater Treatment Facilities
Whats New!!
~~~~~~~~~
-=- Ver. 2.10 - Now allows scheduling PM by meter hours. Reports
available to screen or printer on tasks. Prints only tasks that
are overdue.
- Bug fix for PM work orders.
- Be sure to run CONVERT.EXE for version 2.0 and below.
-=- Ver. 2.11 - Updated manual. Yearly reports on PM tasks completed.
History log added to equipment maintenance. Includes options to
add, view, search, delete, or move the history log of maintenance
tasks completed.
- Printouts available for completed or incomplete work orders.
-=- Ver. 3.00 - Valve maintenance database added to software package.
- Fix small bugs in previous version.
- Because of system size, this package can no longer operate on a
floppy drive system. The system can only be operated from a hard
drive.
- History file update has been expanded so that any maintenance or
updates that are done throughout the system are added.
- Unscheduled tasks will update history logs for equipment and
valves.
- Expanded history log procedures.
- On-line help available to REGISTERED USERS.
-=- Ver. 3.01 - Changed I&M around so the Path setup is easier to use
and to make new directories. Will move files automatically and
delete the old ones.
- REGISTERED USERS - An auxiliary program that will allow rapid and
easy updating of meter hours in the databases. Will signal if a
task requires completion.
2
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
Inventory Control / Preventive Maintenance
For
Water/Wastewater Treatment Facilities
Problems Or Questions
~~~~~~~~~~~~~~~~~~~~~
If you have any problems, questions or features you would like to see
added, contact me, Elmer H. Anderson, at the below listed services....
C/O TrailBlazer Software Systems
1115 B Millersville Avenue
Howards Grove, Wi 53083-1441
Home (414) 565-3512 or Answering Machine
Work (414) 565-3029 0700 - 1530 Howards Grove WWTP
-Leave E-Mail Through Circuit Net To Node 414000 (Software SIG)
-ShadowComm BBS (414) 452-3884
-Compuserve ID 72210,3352 IBMBBS or IBMAPP
Be Sure To Include Your Full Name, Address And Phone Number When
Sending Correspondence.
3
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
Inventory Control / Preventive Maintenance
For
Water/Wastewater Treatment Facilities
INVENTORY CONTROL - PREVENTIVE MAINTENANCE SYSTEM REQUIREMENTS
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Used to program this software:
o Tandy 4020 SX (1M Memory)
o 40 M Hard drive (Recommend 20M + HD)
o 3 1/2" 1.44 floppy for archives
o DMP 130 printer (IBM codes used for printing)
o VGM-200 high resolution monitor
o Microsoft QuickBASIC Version 4.5
SYSTEM CONFIGURATION
~~~~~~~~~~~~~~~~~~~~
In your CONFIG.SYS I would highly suggest that you set it up so that
the
FILES = [10 - 15]
BUFFERS = [20 - 30]
DOS defaults FILES to 10 but I would suggest a higher number like 15.
If you have a HD, I'm sure that the FILES is already set high. The
BUFFERS will allow a faster running program by cutting out the disk
access times. The programs do a lot of file I/O so do not cut these
two numbers short. Because you may be doing a lot of printing, I would
suggest that you install a printer buffer or use SPOOLER.SYS in the
CONFIG.SYS. Since one page usually uses about 1k, a 20k buffer would
probably be sufficient, but if you plan on keeping a lot of records a
buffer of up to 50 - 64k would be recommended.
THIS SOFTWARE SYSTEM CAN NO LONGER BE RUN FROM DUAL 360K FLOPPIES OR
SINGLE 720K DRIVE SYSTEMS. A HARD DRIVE IS REQUIRED.....
4
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
Inventory Control / Preventive Maintenance
For
Water/Wastewater Treatment Facilities
Files needed for this program set are as follows:
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
** I&M.EXE - This is the Registered Version of the main program. This
will allow unlimited record keeping.
I&MP.EXE - This is the Shareware Version of the main program and
will allow only the production of 25 records. But is a
fully working version of I&M.EXE.
EQUIP.EXE - This program is a database to number and track all
equipment in your plant.
PARTS.EXE - This program is a database to number and track all parts
and inventory in your plant.
TRANS.EXE - This program is used to make quick and easy inventory
transactions. Also contains a subprogram to printout
labels for parts (3-9 barcoded labels if needed), mailing
labels for vendors, manufacturers and for plant return
addresses.
WORK.EXE - This program will make and print-out work orders for
scheduled preventive maintenance tasks you have outlined.
This program will updated inventories off of completed
work orders. This program will also printout forecasted
maintenance for the year instead of work orders, you
decide what you want to use.
TASKS.EXE - This program will let you enter in the scheduled
maintenance tasks you want done during the year and then
will automatically plug them into a 52 week maintenance
calendar or based on run time (meter hours).
USTASKS.EXE - This will let you track unscheduled maintenance tasks
that are done when needed. This program will also
generate work orders for these tasks and update
inventories from completed work orders.
VALVE.EXE - This is a database to number and track all of the valves
in you plant.
BRUN45.EXE - These programs where compiled with QuickBasic and this
file is needed to run all of the *.EXE files.
SORT.EXE - This program is the one used in the sort routines. Each
version of DOS has different SORT.EXE. If you have
problems with sorting copy your version to \INVENTOR.
** Designates files included only with REGISTERED VERSIONS.
5
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
Inventory Control / Preventive Maintenance
For
Water/Wastewater Treatment Facilities
** AUXIL.EXE - Misc. programs for REGISTERED USERS to help in data
entry.
** HELP.EXE - Online help program that will read in and display the
*.HLP files.
MANUAL.DOC - This file with, hopefully enough information to get you
going with the program.
** *.HLP - These are the help files.
FILES PRODUCED BY THESE PROGRAMS
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
*.CFG - Configuration files that must remain in the default
directory.
*.LST - These are all of the data files that all of the records
are stored in.
*.BAK - If you select the backup feature I&M will create these
files every time you sort or delete a file.
*.VLV - These files are create from completed tasks for the
valves you have listed in the VALVE database. The *
represents the valve number.
*.HST - These files are create from completed tasks for the
equipment you have listed in the EQUIPMENT database. The
* represents the equipment number.
BATCH FILES INCLUDED WITH THE SOFTWARE SYSTEM
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
GO.BAT - Batch file that will contain any updated information
about I&M. Will also tell you how to get started.
PRINTDOC.BAT - Batch file to print out this manual.
REGISTERED Users recieve a printed copy.
INSTALL.BAT - Batch file to set up hard drive C: default \INVENTOR
directory and will copy all files to that directory.
** Designates files included only with REGISTERED VERSIONS.
6
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
Inventory Control / Preventive Maintenance
For
Water/Wastewater Treatment Facilities
Ok, so what can this program do for you?
Well first let me say this, I have been working in water and
wastewater plants since 1980 and one thing I have noticed is that not
to many places have a good inventory or maintenance program, likewise
for the Village here. One thing is I believe that the "Easy Way Is
The Only Way" and that means doing the best job I can, the fastest,
easiest, and right the first time. I first started working on this
program in 1988 when I started working for the Village and found that
the previous employees had taken most of the knowledge of the
maintenance with them when they left. I found little or no written
information on a maintenance schedule or inventory control, (I just
found a $800 dollar John Crane double seal that we could have used but
converted the pump to a cartridge type, an $800 paper weight!).
Anyway, that is when this software program came to mind and I started
working on it. This past summer we started looking at computers for
the plant and that didn't take much effort, local computer stores and
we had good prices, but then came software. We looked at a few
professional packages and at $1500 - $2500, the Village board threw
everything out the window. Well this software package may not do
everything the more expensive ones do, but for our small plant it fits
the bill. What can this program do for you?
First off, the hardest thing I had to do was set up a preventive
maintenance schedule and I did it the hard way, on a piece of poster
board. Then I set up an inventory control program in a notebook.
This was all good and fine but it was not "The Easy Way". What I have
done is transferred those programs into a software package that does
it all easily and automatically.
MANUFACTURER & VENDOR DATABASE
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
This is a combined program that will set up a database for
manufacturers of equipment in your facility and will also set up a
vendors database for vendors who service that equipment. All this
really is a transfer of business cards into a database. I suggest
completing these databases first, because all of the other programs
will search these databases and add the manufacturers or vendors name
into their databases. I track these manufacturers and vendors by
ASSIGNING THEM AN ARBITRARY NUMBER in the database.
**** NOTE ****
Don't use letters in the NUMBER area of the database, because the
other programs will search for numbers and will not recognize the
letters.
What I do is as I get a business card, I will write say 201 on it,
enter the information from off the card and then file the card in the
back of the bottom drawer.
7
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
MANUFACTURER & VENDOR DATABASE
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
HELPFUL HINTS
~~~~~~~~~~~~~
MANUFACTURER LISTINGS
~~~~~~~~~~~~~~~~~~~~~
Record Number............. : 1
[1] Company Number............ : 1
[2] Company Name.............. : Joes Pump Repair Shop
[3] Address................... : 1111 Jump Street
[4] City...................... : Howards Grove
[5] State..................... : WI
[6] Zip Code.................. : 53083
[7] Company Phone Number...... : 1-414-565-3333
[8] Person To Contact......... : Joe Ext: 555
[9] Person To Contact......... : Mary Ext: 233
Enter # Or...[A]dd...[N]ame Search...[R] Number Search ..[S]ave
..[Q]uit ...[P]rint...[Pg Up]/[Pg Dn] +-Record ..[D]elete...S[O]rt
Records
1.) Company Number. This is a number assigned by you to this
particular company in the database here. This is the number that
the other databases look for when searching for a manufacturer or
vendor. If you number more than one company with this number, the
other databases will take the data from the first number they
come to when searching these databases.
2.) Company Name. This is the name of the company or vendor. You can
use up to 40 characters for this field.
3.) Address and City. This is the address and city of this
particular company. You have 40 characters for address and 25 for
the city field.
4.) State. This is a 2 character field for the state in which the
company is located. It will be automatically capitalized.
The rest of the field should be self explanatory.
5.) Name & Number Search. These options will allow you to rapidly
search for and find company names and numbers by just entering a
few characters. When looking for company names, the less
characters you use the faster the database will locate these
companies. The number search will allow you to immediately jump
to that company number without searching through the database one
number at a time.
6.) Sort Records. This will allow you to sort this database anyway
you want to according to the options listed in the Sort Menu.
This is how the database will be arranged for viewing.
This help bulletin is used for both manufacturing and vendor
databases.
8
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
PARTS DATABASE
~~~~~~~~~~~~~~
This database will definitely help you keep track of the parts you
have around the facility. Because so many different manufacturers and
vendors label their parts so differently, I again have numbered parts,
lubricants, tools, etc. with an ARBITRARY NUMBER and entered all the
information into this database. This inventory database will be
automatically updated from the other programs, work orders or parts
transactions you enter. You can print out different reports to screen
or printer on parts status and will even print out a reorder report
based on the information you enter.
**** NOTE ****
Don't use letters in the NUMBER area of the database, because the
other programs will search for numbers and will not recognize the
letters.
Notice that this database also asks for vendors numbers and
manufacturers numbers so as to allow quick and easy reordering.
HELPFUL HINTS
~~~~~~~~~~~~~
PARTS INVENTORY LISTINGS
~~~~~~~~~~~~~~~~~~~~~~~~
Record # ........... : 1
[1] Part Number......... : 1
[2] Part Description.... : Bearing
[3] Unit Of Measurement. : ea
[4] Main Manufacturer... : 1, Joes Pump Repair Shop
[5] Primary Vendor #.... : 1, Johns Filter Shop
[6] Vendor Part Number.. : 54556-544
[7] Stand-By Vendor #... : 2, Allen Engineering
[8] Vendor Part Number.. : 4334-4
[9] For Equipment # .... : 1, Blower
[0] Storage Location.... : Generator Room
Edit # Or..[A]dd..[N]ame/[U] Number Search .[S]ave .[P]rint
.[R]eports .[Q]uit S[O]rt Records..[Pg Up]/[Pg Dn] +- Record
.[D]elete..[SPACE] Other Screen
Record Number is the physical location of this record on disk.
1.) Part Number. This is a number picked by you to track this part
throughout the various databases. The various databases do not
recognize letters when searching for a part number. If you number
more than one part the same number, the databases will pick the
first record they come to with this number. Be sure that all of
your numbers are different.
2.) Part Description. This is a 40 character field that describes this
particular part.
3.) Unit Of Measurement. This field is how you track the amount of
each part. By the gallon, foot, dozen, each, etc.. This is a
seven character field so be sure to abbreviate any long units of
measurement.
9
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
HELPFUL HINTS
~~~~~~~~~~~~~
PARTS DATABASE
~~~~~~~~~~~~~~
4.) Main Manufacturer. When you enter a manufacturer number here for
this part, it will search the manufacturer database for this
record and then display the number and name of the part
manufacturer.
5.) Primary And Stand-By Vendor. When you enter these numbers, the
database will search the vendors database and find these records.
the database will then display the number and name of the vendor.
6.) Primary And Stand-By Vendors Part Numbers. This will allow you
to enter the vendors part number for this part so that when
reordering this part, the reorder report will show the vendor and
the vendors part number.
7.) Equipment Number. This will allow you to designate the primary
equipment this part would be used for. The database will search
the equipment database for this equipment number and display the
number and name.
8.) Storage Location. This is where the part is stored. I would
suggest keeping the name simple and using the same ones for all
of the databases. When you enter the reports menu, parts can be
sorted and printed by storage location.
10
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
PARTS DATABASE
~~~~~~~~~~~~~~
HELPFUL HINTS
~~~~~~~~~~~~~
PARTS INVENTORY LISTINGS
~~~~~~~~~~~~~~~~~~~~~~~~
Part Number... : 1 : Bearing
[1] Reorder Level............. : 2.00 ea
[2] Reorder Quantity (Units).. : 4.00 ea Reorder Cost.. :$ 100.00
[3] Quantity On Hand.......... : 0.00 ea In Inventory.. :$ 0
[4] Unit Cost................. : $ 25.00 ea
[5] Date Of Last Count........ : 07-07-91
Quantity Last Used........ : 0.00 ea
Date Of Last Use.......... : 07-07-91
Quantity Used Since....... : 07-07-91 # Used. : 1 Cost :$ 25
[6] Date Of Last Purchase..... : 07-07-91
[7] Quantity Last Purchase.... : 4.00 ea
[8] Vendor Last Purchase From. : 2, Allen Engineering
Enter # To Edit Or...[SPACE]..Main Screen
1.) Reorder Level. This is the level at which you want to initiate
reordering of this part.
2.) Reorder Quantity. This is how many units you want to reorder,
when placing an order.
Reorder Cost. This is how much it would cost you to reorder the
quantity you desire.
3.) Quantity On Hand. This is the count of how much of this part you
have in inventory.
In Inventory. This is the cost of the parts you have in
inventory.
4.) Unit Cost. This is the average cost per unit of this part you
have in inventory. This is the cost that all of the other fields
use when determining cost.
5.) Date Of Last Count. This is when you physically counted each of
these parts. When completing this field, leaving the filed blank
and hitting enter will put in todays date.
6.) Quantity Last Used. This is how many of this part that was used
the last time maintenance was completed and required this part.
This is a number updated from completed work orders or inventory
transactions.
7.) Date Of Last Use. This is a field updated from work orders that
shows when this part was last needed.
8.) Quantity Used Since. This field is a sum of how many units of
this part was used since the date shown, how many have been used
and the total cost to date. This field is updated from completed
work orders and can be cleared to zero and todays date by using
the [C] option from the reports menu to Clear Accumulator Fields.
11
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
THE LABEL MAKER AND INVENTORY TRANSACTIONS
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
This program will make updating the inventory database very easy. All
you need is the part number and the program will bring up that part
record. You can then add a part to inventory or take one out as you
use it. This program will also make adding a part to the inventory
list quick and easy. This program will also make labels for all of
your parts you may have stored in the inventory database. It uses 2"
- 4" wide single labels, (cheap ones) x 15/16". It will print out 3-9
barcoded labels if you request them or labels without the barcode and
containing more information on the part. I use these and label all of
the storage items we have. It will also print out plant return
labels, manufacturer labels or vendor labels. We enter in the DNR and
EPA into the vendor database and print those out for a more
professional appearance on our correspondence.
HELPFUL HINTS
~~~~~~~~~~~~~
PART LABEL PRINTOUT
~~~~~~~~~~~~~~~~~~~
Without 3-Of-9 Code Bar
╔═══════════════════════════════╗
║Part # 1 ║
║ ║ 3.0~ x 15/16~ Label
║Bearing ║ 1 Copies To Be Made
║Blower ║ 1 Spaces Between Labels
║2, Allen Engineering ║
╚═══════════════════════════════╝
[1] Enter Part Number [<ENTER> = All]
[2] Change Label Configuration
[3] Change # Of Copies To Be Printed
[4] Print Labels
[Q] Quit
1.) Enter Part Number. Enter the part number that you want a label
printed out for. The program will search the parts database and
insert the above information to printed on the label. If you hit
<ENTER>, labels will be printed for all of the parts in the parts
database.
2.) Change Label Configuration. This will change the size of the
labels you are using. Options available are 2.5~, 3.0~, 3.5~ and
4.0~ x 15/16~. I selected just these options because these labels
are readily available and not to expensive. The other option is
the space between labels. The reason for this is that some labels
are spaced differently. All of the ones I use are just one space
apart, but I have had some that are 2. Just try a couple and see.
3.) If you choose the option to make 3-9 barcode labels, it will take
a while for the labels to print because graphic codes are sent to
the printer. The barcode option doesn't have the room for all of
the data like the above label. It prints only the part number and
part description.
12
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
EQUIPMENT RECORD KEEPING
~~~~~~~~~~~~~~~~~~~~~~~~
This is the program that I have spent many an hour trying to perfect,
it took a while but I think it now does a great job. It will let you
enter in all of the important information about a piece of equipment,
(if you are using a equipment record card now, most of the information
on the top of the card is recorded in this database). What I have done
is went thru the plant and ARBITRARILY NUMBERED all of the equipment.
Again realize that this database works on numbered equipment and not
lettered equipment.
**** NOTE ****
Don't use letters in the NUMBER area of the database, because the
other programs will search for numbers and will not recognize the
letters.
This database will be automatically updated from completed work
orders.
HELPFUL HINTS
~~~~~~~~~~~~~
EQUIPMENT LISTINGS
~~~~~~~~~~~~~~~~~~
Record # ........... : 1
[1] Equipment Number.... : 1
[2] Equipment Desc. 1... : Process Blower
[3] Equipment Desc. 2... : Nothing
[4] Storage Location.... : Blower Room
[5] Manufacturer Number. : 1, Joes Pump Repair Shop
[6] Vendor Number....... : 1, Johns Filter Shop
[7] Model Number........ : 2222
[8] Serial Number....... : 3333
Edit # Or..[A]dd..[L] Log..[N]ame/[U] Number Search ..[S]ave ..[P]rint
..[Q]uit.. S[O]rt Records..[Pg Up]/[Pg Dn] +- Record ..[D]elete
..[SPACE] Other Screen
1.) Equipment Number. This is a number assigned by you to designate
this piece of equipment. The databases do not recognize letters,
so be sure to use only numbers. The number may be up to 8 numbers
long. The program will accept 10 characters, but I will change
that in the future. The reason you should only use 8 numbers is
that a separate history file is created and the numbers are use to
designate this file in DOS. If you use 9 or 10 numbers, DOS will
only use the first 8.
2.) Equipment Description 1 & 2. These fields will accept up to 40
characters each so that you can describe in detail just what this
equipment is. The first field is the field all of the databases
will use to describe the equipment, so detail it so that you will
know what equipment it is at a glance. The number and description
will appear in the other databases like this-----> 1, Process
Blower <---- from the above given description.
13
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
EQUIPMENT RECORD KEEPING
~~~~~~~~~~~~~~~~~~~~~~~~
HELPFUL HINTS
~~~~~~~~~~~~~
3.) Storage Location. This is the location of this equipment or
where it is stored when not in use. Keep this description
generalized and the same as the other databases so that it will
make for easy sorting in all of the databases.
4.) Manufacturer & Vendor Numbers. Enter in the manufacturer or
vendors number and the program will search the database for
manufacturers and vendors and will import the name of the company
and display as above.
SCREEN #2
Equipment Database Helpful hints Screen #2
~~~~~~~~~
EQUIPMENT LISTINGS
~~~~~~~~~~~~~~~~~~
Equip Number.. : 1 : Process Blower
[1] Equipment Type............ : Blower
[2] Equipment Size..(ie HP)... : 60
[3] Motor Volts............... : 460
[4] Motor Amps................ : 75
[5] Motor RPM................. : 3500
[6] Equip Capacity..(ie GPM).. : 650 cfm
[7] Date Of Purchase.......... : 07-06-91
[8] Date Put In Service....... : 07-06-91
[9] Current Meter Reading..... : 7600
[0] Date Meter Read........... : 07-07-91
Enter # To Edit Or...[SPACE]..Main Screen
1.) Equipment Type. Keep this simple and direct. Like pump or
blower. This is used for sorting only and makes for putting like
equipment into the same groupings.
14
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
EQUIPMENT LOG
~~~~~~~~~~~~~
Option [L] from the main menu
EQUIPMENT HISTORY
~~~~~~~~~~~~~~~~~
[1] Add To Equipment History Log
[2] Move History Log To Floppy Drive
[3] Delete History Log By Date
[4] View History Log By Date
[5] View History Log From Different Drive/Directory
[6] Search History Log
[Q] Quit Main Menu
1.) Add To Log. This option will allow you to manually add task
history to the history file of this piece of equipment. This is
for past history you want added to the file, work done without a
work order or any other reason. Options include adding Task # 1,
Date task completed, total parts cost, meter reading at time of
work completion, the man hours required, and who the work was
completed by.
2.) Move History. This allows you to move certain parts of the
history to a floppy drive or any other directory. Allows moving
by date so old data can be moved out.
3.) Delete History. Allows deleting of data by date.
History files can be viewed and edited from DOS using a text editor,
don't use a word processor. The fields are as follows...
Equipment # & name, Task #1, Date completed, Meter hrs, man hrs, parts
$, and completed by.
Be careful not to disturb the fields, you can change any of the data
within the quotations, but be sure not to erase any of the Quotation
marks.
15
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
SCHEDULED MAINTENANCE TASK LISTING
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
If I could only described to you the problems I had with this program.
It took almost two days of dedicated mental anguish to get something
to work, but alas its here and works great. The preventive
maintenance program I set up at Howards Grove was based on the
original plant maintenance program set up by the engineering firm when
the plant was built. What they had done was put all of the scheduling
together based on calendar days and was similar to the one I had
worked with in the Army. I was finally able to transfer that program
into a software based package that automatically separated and filed
all of the different tasks to be done, based on calendar days. The
program will also track meter hours and will sound an alarm if
maintenance is due whenever meter hours are entered into the system
from any of the programs.
** This is tracked only if you enter a time in hours into item [6]
otherwise the program will ignore the meter tracking option.
Anyway, this program will let you define the task and then will ask
you if it is a daily, weekly, bimonthly, monthly, 2,3,4,6 month,
1,2,3,5 year task and will plug it into a 52 week calendar. The
program will automatically separate the tasks so you don't do 10,
6-month tasks in one week and none till six months later. It will ask
on the six month if it is a spring-fall or a winter-summer combination
so you won't be changing oil in a clarifier drive in the middle of
January and on 1,2,3,5 year tasks it ask you if it is a summer or
winter task.
It will also let you add in tools or parts you may need for the job
and can be printed out on a task listing sheet or on a work order.
The only draw back to this auto plug in of tasks is the monthly task.
Instead of doing it 12 times a year, with this program you will do it
13 times. This can be ok because you will do every 4 weeks and would
be more regular.
16
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
HELPFUL HINTS
~~~~~~~~~~~~~
PREVENTIVE MAINTENANCE TASKS
~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Record # ..... : 1
[1] Equipment #... : 1, Process Blower
[2] Task 1... : Repack Bearings
[3] Task 3... :
[4] Task 3... :
[5] Date Last Done : 07-07-91
Meter Reading. : 7600 Accumulated Time.. : 0
[6] Schedule Hrs.. : 1500
[7] Schedule Days. : Monthly
[8] Priority (1-5) : 1 - Emergency!
[9] Man Hrs Needed : 4
[0] Completed By.. : Elmer & Dave
[T] This Record Only, [A] All Records, [W] Work Order, or [Q] Quit
Edit # Or..[A]dd..[N]ame/[U] Number Search..[S]ave..[P]rint..[Q]uit
S[O]rt Records..[Pg Up]/[Pg Dn] +- Record..[D]elete..[SPACE] Other
Screen
1.) Equipment Number. This is the equipment that will be worked on.
Enter in the equipment number and the program will search the
equipment database for this number & enter in the equipment
description. This works the same for the valve maintenance tasks.
2.) Task 1. This is the main task that is used through out the
databases. It is the task description that will be used in the
equipment and valve history logs. Used a short but descriptive
sentence to describe the task so that you will know the task when
seen in the other databases.
3.) Task 2 & 3. These are additional 40 character fields to help
describe this maintenance task. These descriptions will not be
used outside this database.
4.) Date Last Done. This is the date this task was last completed.
This field will be updated from completed work orders and other
databases. Notice the date format, this is the format used
throughout the databases.
5.) Meter Reading. This is a field that will be updated from completed
work orders and other databases.
Accumulated Time. This is only shown if you have time shown in
Scheduled Hours. This is an ongoing total that is used to
determine when this task should be completed. Once this task has
been completed, it will be reset to zero.
6.) Scheduled Hours. This allows for scheduling maintenance by meter
hours. If you enter in any time at all, the task will be
completed by hours or by calendar time that you designate in
Scheduled Days. If you do not wish to track maintenance by
Do not enter in any numbers or zero.
17
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
HELPFUL HINTS
~~~~~~~~~~~~~
PREVENTIVE MAINTENANCE TASKS
~~~~~~~~~~~~~~~~~~~~~~~~~~~~
7.) Scheduled Days. This is the meat an potatoes of I&M. Enter in
the calendar time that you want this task completed on. The
database will automatically plug that calendar time into a master
time schedule.
8.) Priority. Using the enclosed table, designate what type of
priority to use on this maintenance task when it comes due.
9.) Print. To print a work order for this task from the tasks
database, use the PRINT option. As seen above, work orders for
this task are part of the printing options available.
SCREEN #2
~~~~~~~~~
PREVENTIVE MAINTENANCE TASKS
~~~~~~~~~~~~~~~~~~~~~~~~~~~~
Equipment 1, Process Blower
Part/Tool # Part Or Tool Description Est. Qty.
----------------------------------------------------------------------
[1] ** Not Used **
[2] ** Not Used **
[3] ** Not Used **
[4] ** Not Used **
[5] ** Not Used **
[6] ** Not Used **
[7] ** Not Used **
[8] ** Not Used **
[9] ** Not Used **
Enter # To Edit Or...[SPACE]..Main Screen
1.) Part/Tool #. Enter in any or all part numbers of parts in
inventory that might be required to complete this task. The
program will search the parts database and import the part
description. Then enter in the estimated quantity that might be
needed. This will be print on the work order so that workers will
have a good ideas of parts they will need, and this will allow for
quick and easy parts inventory updates from completed work orders.
Hitting <ENTER> will bring up the ** Not Used **.
18
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
UNSCHEDULED MAINTENANCE TASK LISTING
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
This database is for those tasks that you just can't schedule, like
changing a blower filter or something of this nature. It will do
everything that the regular task listing program will do, but will ask
you for times a year the task is done and will not plug it into a
schedule. Basically if you find that the task needs to be done, it
can print out a work order for the job and you can get it done. It
will let you update the work order. It will print out a task listing
if you don't use the work order option.
HELPFUL HINTS
~~~~~~~~~~~~~
UNSCHEDULED MAINTENANCE
~~~~~~~~~~~~~~~~~~~~~~~
Record # ..... : 1
[1] Equipment #... : 1, Process Blower
[2] Task 1... : Realign Coupler
[3] Task 3... :
[4] Task 3... :
[5] Date Last Done : 07-07-91
Meter Reading. : 7600
[6] Times/Year.... : 2
[7] Priority (1-5) : 1 - Emergency!
[8] Man Hrs Needed : 2
[9] Last Done By.. : Elmer
[T] This Record Only...[A] All Records...[W] Work Order...[Q] Quit
Edit #.[A]dd..[N]ame/[U] Number Search..[S]ave..[P]rint.[W] Work
Orders.[Q]uit..S[O]rt Records..[Pg Up]/[Pg Dn] +- Record ..[D]elete
..[SPACE] Other Screen
1.) Equipment Number. This is the equipment that will be worked on.
Enter in the equipment number and the program will search the
equipment database for this number & enter in the equipment
description. This works the same for the valve maintenance
tasks.
2.) Task 1. This is the main task that is used through out the
databases. It is the task description that will be used in the
equipment and valve history logs. Used a short but descriptive
sentence to describe the task so that you will know the task when
seen in the other databases.
3.) Task 2 & 3. These are additional 40 character fields to help
describe this maintenance task. These descriptions will not be
used outside this database.
4.) Date Last Done. This is the date this task was last completed.
This field will be updated from completed work orders and other
databases.
5.) Meter Reading. This is a field that will be updated from completed
work orders and other databases.
19
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
HELPFUL HINTS
~~~~~~~~~~~~~
UNSCHEDULED MAINTENANCE
~~~~~~~~~~~~~~~~~~~~~~~
6.) Times/Year. This is just a reminder to the user on how many
times a year that this should be completed. This task is not
plugged into a time schedule or maintenance calendar.
7.) Priority. Using the below table, designate what type of priority
to use on this maintenance task when it comes due.
8.) Print. To print a work order for this task from the tasks
database, use the PRINT option. As seen above, work orders for
this task are part of the printing options available.
SCREEN #2
~~~~~~~~~
UNSCHEDULED MAINTENANCE
~~~~~~~~~~~~~~~~~~~~~~~
Equipment #.. : 1, Process Blower
Part/Tool # Part Or Tool Description Est. Qty.
----------------------------------------------------------------------
[1] 1, Bearing 1
[2] ** Not Used **
[3] ** Not Used **
[4] ** Not Used **
[5] ** Not Used **
[6] ** Not Used **
[7] ** Not Used **
[8] ** Not Used **
[9] ** Not Used **
Enter # To Edit Or...[SPACE]..Main Screen
1.) Part/Tool #. Enter in any or all part numbers of parts in
inventory that might be required to complete this task. The
program will search the parts database and import the part
description. Then enter in the estimated quantity that might be
needed. This will be print on the work order so that workers
will have a good ideas of parts they will need, and this will
allow for quick and easy parts inventory updates from completed
work orders. Hitting <ENTER> will bring up the ** Not Used **.
2.) This is the second screen in the work orders update. If a part
had been entered into the task listings then it would appear
here. Enter in the option number and the actual amount used. If
this data is saved then the parts inventory will be updated also.
20
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
HELPFUL HINTS
~~~~~~~~~~~~~
UNSCHEDULED MAINTENANCE
~~~~~~~~~~~~~~~~~~~~~~~
UPDATE WORK ORDERS
~~~~~~~~~~~~~~~~~~
Record # ..... : 1
Work Order #.. : 1
Equipment #... : 1, Process Blower
Task 1... : Realign Coupler
Task 2... :
Task 3... :
[1] Date Completed : 07-07-91
[2] Meter Reading. : 2540
[3] Man Hrs Needed : 2
[4] Completed By.. : John
Edit # Or...[N] Number Search...[Pg Up]/[Pg Dn] +- Record...
[R] Reset Work Order Attribute...[SPACE] Other Screen...[Q]uit
1.) When you print out work orders for tasks to be completed, a
separate database is compiled to track the work orders. Data
above has been compiled from a work order printout. Options 1 -
4 are left blank. When the task has been completed, come to this
screen, work order updates, to update information.
-Enter in the date it was completed, or <ENTER> and todays date
will be entered.
-Enter in the current meter reading.
-Enter man hours the task required to be completed.
-Enter who completed the task.
Hit [S] to save the data and to update all of the other databases.
If you hit [Q] to quit or any of the other options to move from
this record after you have entered in data, the program will ask
you if you want to save the data.
2.) Notice the date format. This is the date format used in all of
the databases.
3.) Once this data has been saved, you cannot change any of the data
in the record. The reason for this is that it would screw up the
parts inventory. To change any of the above information, you
will have to go to the separate databases and update the
information manually.
21
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
WORK ORDER AND TASK LISTING FOR SCHEDULED MAINTENANCE
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
This program will generate task listings by week for the year or for
the whole year, depending on your needs for future scheduling. These
task listings may be sent to the screen or printer.
This program will also generate work orders for scheduled tasks, by
the week or for the whole year. I never used work orders before, but
once I started I will probably not go back. Anyone can pick up a work
order, know what equipment needs to be worked on, location, tasks to
be done, tools needed or parts needed and not need a lot of prior
research to get something done. I use completed work orders for use
as the bottom half of equipment record sheets. I file these for
written confirmation of the completed task. There is plenty of room
on the work orders for additional comments by the employee, (the
backside is completely open for drawings, scribbles etc.) and makes it
easy to update the database records.
When you use this option a separate database is constructed to store
the work order numbers, so you can search and update work orders
quickly and easily.
HELPFUL HINTS
~~~~~~~~~~~~~
WORK ORDERS
Record # ..... : 1 ~~~~~~~~~~~
Work Order #.. : 6
Equipment #... : 1, Process Blower
Task 1... : Repack Bearings
Task 2... :
Task 3... :
[1] Date Completed : 07-07-91
[2] Meter Reading. : 6000
[3] Man Hrs Needed : 3
[4] Completed By.. : Elmer
Edit #.[N] Nmb Srch.[Pg Up]/[Pg Dn] +- Record.[SPACE] Other Scn.[Q]uit
1.) When you print out work orders for tasks to be completed, a
separate database is compiled to track the work orders. Data
above has been compiled from a work order printout. Options 1 -
4 are left blank. When the task has been completed, come to this
screen to update information.
-Enter in the date it was completed, or <ENTER> and todays date
will be entered.
-Enter in the current meter reading.
-Enter man hours the task required to be completed.
-Enter in who completed the task.
Hit [S] to save the data and to update all of the other
databases.
If you hit [Q] to quit or any of the other options to move from
this record after you have entered in data, the program will ask
you if you want to save the data.
2.) Notice the date format. This is the date format used in all of
the databases.
22
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
HELPFUL HINTS
~~~~~~~~~~~~~
3.) Once this data has been saved, you cannot change any of the data
in the record. The reason for this is that it would screw up the
parts inventory. To change any of the above information, you
will have to go to the separate databases and update the
information manually.
SCREEN #2
~~~~~~~~~
WORK ORDERS
~~~~~~~~~~~
Equipment #.. : 1, Process Blower
Part/Tool # Part Or Tool Description Actual Quantity Used
----------------------------------------------------------------------
[1] ** Not Used **
[2] ** Not Used **
[3] ** Not Used **
[4] ** Not Used **
[5] ** Not Used **
[6] ** Not Used **
[7] ** Not Used **
[8] ** Not Used **
[9] ** Not Used **
Enter # To Edit Or...[SPACE]..Main Screen
This is the second screen in the work orders update. If a part had
been entered into the task listings then it would appear here. Enter
in the option number and the actual amount used. If this data is
saved then the parts inventory will be updated also.
23
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
VALVE RECORD KEEPING
~~~~~~~~~~~~~~~~~~~~
This database is based on the equipment database, but will track
valves in your facility. It will let you enter in all of the
important information about a valve. It will set up a separate
database for scheduling maintenance. What I have done is went thru the
plant and ARBITRARILY NUMBERED all of the valves. Again realize that
this database works on numbered valves and not lettered valves.
**** NOTE ****
Don't use letters in the NUMBER area of the database, because the
other programs will search for numbers and will not recognize the
letters.
This database will be automatically updated from completed work
orders.
HELPFUL HINTS
~~~~~~~~~~~~~
VALVE LISTINGS
~~~~~~~~~~~~~~
Record # ........... : 1
[1] Valve Number........ : 1
[2] Valve Description 1. : Raw Wastewater Valve
[3] Valve Description 2. : Nothing
[4] Valve Location...... : wet well
[5] Manufacturer Number. : 1, Joes Pump Repair Shop
[6] Vendor Number....... : 1, Johns Filter Shop
[7] Model Number........ : 434
[8] Serial Number....... : 6766
Edit # Or .[A]dd .[L] Log .[N]ame/[U] Number Search .[S]ave .[P]rint
.[Q]uit S[O]rt Records..[Pg Up]/[Pg Dn] +- Record..[D]elete..[SPACE]
Other Screen
1.) Valve Number. This is a number assigned by you to designate this
valve. The databases do not recognize letters, so be sure to use
only numbers. The number may be up to 8 numbers long. The
program will take 10 letters, but I will change that in the
future. The reason you should only use 8 numbers is that a
separate history file is created and the numbers are use to
designate this file in DOS. If you use 9 or 10 numbers, DOS will
only use the first 8.
2.) Valve Description 1 & 2. These fields will accept up to 40
characters each so that you can describe in detail just what this
valve is. The first field is the field all of the databases will
use to describe the valve, so detail it so that you will know
what valve it is at a glance. The number and description will
appear in the other databases like this-----> 1, Raw Wastewater
Valve <---- from the above given description.
3.) Valve Location. This is the location of this valve or where it
is stored when not in use. Keep this description generalized and
the same as the other databases so that it will make for easy
sorting in all of the databases.
24
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
VALVE RECORD KEEPING
~~~~~~~~~~~~~~~~~~~~
HELPFUL HINTS
~~~~~~~~~~~~~
4.) Manufacturer & Vendor Numbers. Enter in the manufacturer or
vendors number and the program will search the database for
manufacturers and vendors and will import the name of the company
and display as above.
SCREEN #2
~~~~~~~~~
VALVE LISTINGS
~~~~~~~~~~~~~~
Valve Number.. : 1 : Raw Wastewater Valve
[1] Valve Type................ : Plug
[2] Valve Size (in)........... : 4
[3] Material Handled.......... : Raw wastewater
[4] Date Of Purchase.......... : 07-06-91
[5] Date Put In Service....... : 07-06-91
Enter # To Edit Or...[SPACE]..Main Screen
1.) Valve Type. Keep this simple and direct. Like pump or blower.
This is used for sorting only and makes for putting like valves
into the same groupings.
25
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
VALVE LOG
~~~~~~~~~
Option [L] from the main menu
VALVE HISTORY
~~~~~~~~~~~~~
[1] Add To Valve History Log
[2] Move History Log To Floppy Drive
[3] Delete History Log By Date
[4] View History Log By Date
[5] View History Log From Different Drive/Directory
[6] Search History Log
[Q] Quit Main Menu
1.) Add To Log. This option will allow you to manually add task
history to the history file of this valve. This is for past
history you want added to the file, work done without a work
order or any other reason. Options include adding Task # 1, Date
task completed, total parts cost, the man hours required, and who
the work was completed by.
2.) Move History. This allows you to move certain parts of the history
to a floppy drive or any other directory. Allows moving by date so
old data can be moved out.
3.) Delete History. Allows deleting of data by date.
History files can be viewed and edited from DOS using a text editor,
don't use a word processor. The fields are as follows...
Valve # & name, task #1, date completed, <BLANK> , man hrs, parts $,
and completed by.
Be careful not to disturb the fields, you can change any of the data
within the quotations, but be sure not to erase any of the quotation
marks.
Well anyway, the software system should be self explanatory, I have
tried to make it so, but I am sure you might run into a nasty bug or
maybe have a problem somewhere or sometime. If so, please feel free
to contact me at the above listed numbers or services. I work 0700 to
1530 each day. If you call my home number, I have a answering
machine. Please leave your name and number, I will get back to you.
26
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
Inventory Control / Preventive Maintenance
For
Water/Wastewater Treatment Facilities
START-UP
~~~~~~~~
Ok, lets get this thing rolling.
1.) Print out the MANUAL.DOC. This is in ASCII so can be read from
DOS. PLEASE READ readme.txt BEFORE CONTINUEING.
2.) Copy all *.EXE files to one directory. Be sure that there is about
an extra 1.5k so that *.CFG files can be added or use INSTALL to
put everything onto hard drive C:.
3.) If you have the Shareware version, make sure you have an extra 69k
open for the *.LST files. If you select the BACKUP option, double
your k to 136k for backup storage.
If you are a Registered user then make extra space as follows:
MANUFACT.LST 200 Bytes per record for Manufacturers Database
VENDOR.LST 200 Bytes per record for Vendors Database
PARTS.LST 401 Bytes per record for Parts Catalog
EQUIP.LST 361 Bytes per record for Equipment Database
TASKS.LST 781 Bytes per record for Scheduled Maintenance Tasks
USTASKS.LST 780 Bytes per record for Un-Scheduled Maintenance Tasks
VALVE.LST 311 Bytes per record for Valve Database
If you set your record levels at 100 then you will need 304,400 Bytes
for the *.LST files, an additional 305k if you use backups, and an
additional 701 bytes per work order you create. This is why a hard
drive is needed for this software package. The amount of records you
are limited to your storage space available.
4.) From DOS enter I&M if you are a using a Registered Version.
From DOS enter I&MP if you are a using a Shareware Version.
5.) If this is the first time you have used the program, then it must
create the configure files.
a.) First screen is the General Information File.
1. Enter your facility name as you want it to appear on address
labels, in the programs themselves and on reports that are
generated.
2. Next enter your facility mailing address.
3. Enter your city.
4. Enter your state. Automatic uppercase conversion.
5. Enter your complete 9 digit zip code.
6. Enter facility superintendent.
7. Enter in a master password. This is used only as a fail-safe
for deletions throughout the programs.
8. Enter in if you want backups or not. This was mentioned above.
If you a enter a "Yes" then every time there is a file
manipulation, a backup will be created. Defaults to "NO".
27
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
Inventory Control / Preventive Maintenance
For
Water/Wastewater Treatment Facilities
HELPFUL HINTS
~~~~~~~~~~~~~
Program General Configuration Menu
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
[1] Plant Name.... : Howards Grove Wastewater Treatment Facility
[2] Address....... : 1111 Alcott Ave
[3] City.......... : Howards Grove
[4] State......... : WI
[5] Zip........... : 44444
[6] Phone #....... : 555-555-5555
[7] Superintendent : John Doe
[8] System Password: ********
[9] Backups (y/N). : NO
Enter [#] Number To Change.....[S] To Save Changes.....[Q] To Quit
1.) Plant Name. This is the name that will appear on all of the
screens and printouts throughout all of the databases.
2.) System Password. This is a password that is used throughout the
databases just as a second blanket check so that you or anyone
else does not erase accumulators or delete any other fields.
This password is case sensitive. If you happen to forget what you
chose, just look at MASTER.CFG and you will spot it on line 24.
3.) Backups. This option will make backups of the *.LST files or
database record files prior to doing anything with them, like
sorting. If anything does happened suring any operations, look
for *.BAK in the data directory. Delete the bad *.LST and rename
the *.BAK to *.LST. (The * stands for the various database names,
like EQUIP.LST for the equipment database) This option defaults
to [NO], because of the extra storage space it would require, but
I would suggest using it if possible.
b.) The second screen that appears is the file path and record
Paths And Directories
number screen. Enter in location of your data drive or data
directory.
EXAMPLE: If your data drive is DRIVE B then enter just B. The entry
will appear B:\. Next if your directory is INVENTOR, then
enter INVENTOR and hit ENTER. The entry will appear as
B:\INVENTOR\ which is normal.
**** NOTE ****
Directory can be up to eight letters long.
28
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
**** Registered Version Only *****
After you have entered in the path, the program will ask you for the
amount of records you wish to enter for each individual *.LST file.
Based on the above data on *.LST files, enter in the amount of records
you would like to keep for each individual area.
**** NOTE ****
These entries may be changed later if you feel you need more or less
room.
c.) Next menu is the Color Configuration Menu.
Color Configuration Menu
~~~~~~~~~~~~~~~~~~~~~~~~
0 = Black
1 = Blue
2 = Green [1] Background Color = 0
3 = Cyan [2] Brackets Color = 15
4 = Red [3] Lower Menu Color = 1
5 = Magenta [4] Highlight Color = 2
6 = Brown [5] Warning Color = 4
7 = Grey [6] Menu Color = 14
8 = Dark Grey [7] Underline Color = 15
9 = Light Blue [8] Menu Names Color = 14
10 = Light Green
11 = Light Cyan
12 = Light Red [S] Save Defaults
13 = Light Magenta [Q] Quit To Main Menu
14 = Yellow
15 = White
1.) These are the screen colors as you want to see them. Some
users may not be able to display all of these colors because
they use Tandy Colors and a Tandy CGA monitor. Most should
be able to display at least 4 colors. If all else fails,
set the background to [0] and all the rest to [15]. This
will make a black screen with white foreground letters.
2.) Be sure to save your defaults before leaving this menu or
you will loose what you have changed.
7.) This will complete the setup and bring you into the main menu
screen.
8.) If you made an error in the above setup, now is the time to enter
into the configuration menus and change any incorrect data.
[G] will enter you into the General Configuration menu where you can
change the plant name, address, etc..
[P] will enter you into the Path Setup and Records menu where record
lengths and paths may be changed.
[C] will enter you into the Color Menu were colors can be edited.
**** NOTE ****
If you make a directory change, the data kept in the previous
directory will be moved and deleted. The program will also move any
*.BAK files in the directory.
29
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
Inventory Control / Preventive Maintenance
For
Water/Wastewater Treatment Facilities
**** NOTES ****
~~~~~~~~~~~~~~~
INSTALLING ONLINE HELP
~~~~~~~~~~~~~~~~~~~~~~
** REGISTERED USERS ONLY **
Online help are modules of ASCII information that can be brought up on
the main menu screen to help with the various programs. It is the
same information contained in this manual. To install HELP copy all
of the *.HLP files from Disk B (3.5~) or Disk C (5.25~) along with the
program HELP.EXE to the default directory of I&M.EXE. To enter Online
Help from the main menu of I&M, just press F2.
POSSIBLE ERRORS
~~~~~~~~~~~~~~~
1.) Errors you might run into. The whole program is compiled with
QuickBasic, so any error codes will be basic error codes.
53 = File not found. Make sure you have the right directory path.
62 = Input past end. This one will pop up if you try the sort
option in any of the programs and you don't have any entries
or you only have one entry in that database.
75,76 = Path errors. This one will pop up if you do not enter a path
that is correct. Like a directory spelling error or an extra
":" or "\" is in the directory option.
** I have eliminated most of the problems that will cause these
errors, but if you should happen to have an error of some kind, please
contact me and let me know what you were doing when the error accured
and which sub program you where using.
* * * * * * PLEASE READ NUMBER 2 * * * * * *
~~~~~~~~~~~~~~~~~~~~
2.) Remember, each of the databases use ARBITRARY NUMBERS PICKED BY
YOU, THE USER. Remember to use numbers and not letters. The record
number in red is just the files physical location in relation to the
disk drive. Option [1] on all of the databases is the NUMBER ASSIGNED
BY YOU and is the number used throughout the software package to
identify that particular record.
When you get to the TASK DATABASES, be sure to COMPLETE at least the
Name 1 option after the equipment identifier number, Option [2]. This
first task name along with the equipment identifier number & name will
identify the work order when you go to update work order records.
30
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
Inventory Control / Preventive Maintenance
For
Water/Wastewater Treatment Facilities
**** NOTES ****
~~~~~~~~~~~~~~~
3.) In the programs themselves, [E] will bring up Equipment listing,
an [M] will bring up Manufacturers listings and [V] will bring up
Vendors listings. When searching files [Pg Up] & [Pg Dn] will
move records one at a time, but [~] & [`] on number pad will move
records 10 at a time. [8] [2]
4.) If you run into a lock up in one of the programs or just want to
quit the program, then just hit [F10]. This will quit to DOS
immediately.
5.) If during printout you need the computer [F1] will quit the
printing and will bring you to the nearest main menu.
REGISTRATION
~~~~~~~~~~~~
I realize that this program works for me and might not meet your
needs. But if you think that it might work, then send the
registration price along to me. If you have sent me $10 for a
shareware version through the mail, then subtract that $10 from the
registration price. Don't worry about not getting support for this
software package from me, I take pride in my work and will stand
behind this package 100%.
If you find a major problem or nasty bug and help me in working that
problem out, I will refund to you a portion of the registration price
based on how severe the problem is and how much you help me in solving
the problem. If you find a major problem or nasty bug in a shareware
version and help with that problem, I will send you a Registered
version of this software package free of charge.
SUPPORT
~~~~~~~
I am in the process of putting my BBS back together and will have it
up on a limited basis in the future. If you are a registered user,
you will be notified by postcard of when the BBS will be operating.
You will also be given a password that would allow you access to
updated versions of TrailBlazer Programs. This is still pending.
You are encouraged to pass a Shareware copy of Inventory Control /
Preventive Maintenace along to your friends for evaluation. Please
encourage them to register their copy if they find that they can use
it. All registered users will receive a copy of the latest version
of Inventory Control / Prevetnive Maintenance system.
Thank you for your support of Shareware thru Registration.
Andy
31
Copyright (C) 1990, 1991 By Elmer H. Anderson. All Rights Reserved
┌───────┬──────────────────────────────────────────────────────────────────────┐
│NUMERIC│ PREVENTIVE MAINTENANCE PRIORITY MATRIX │
├───────┼──────────────────────────────────────────────────────────────────────┤
│ │ EMERGENCY! │
│ │ ~~~~~~~~~ │
│ │Immediate Response of all NECESSARY RESOURCES WITHOUT LIMITATION. │
│ │ A. The work is imperative. │
│ │ B. Overtime will be worked around-the-clock until competion. │
│ 1 │ C. Communications will be continuous with management. │
│ │ D. Work cannot be formally planned and scheduled but will be │
│ │ given all resources that can be effectively utilized. │
│ │ E. Every effort will be made to complete at least temporary │
│ │ corrective action and final completion when practical. │
├───────┼──────────────────────────────────────────────────────────────────────┤
│ │ URGENT │
│ │ ~~~~~~ │
│ │Immediate Response with APPROPRIATE RESOURCES. │
│ │ A. Work is essential. │
│ │ B. Automatic overtime to stabilize conditions. │
│ 2 │ C. Communication is continuous with feedback from maintenance │
│ │ to operations. │
│ │ D. Resources will be committed as appropriate to meet dates. │
│ │ E. Action plan is prepared with responsibilites assigned. │
│ │ F. Work may be "two phase" with permananent corrective action │
│ │ done under lower priority at later time. │
├───────┼──────────────────────────────────────────────────────────────────────┤
│ │ IMPORTANT │
│ │ ~~~~~~~~~ │
│ │Necessary Work to be Investigated Immediately and Scheduled to │
│ │meet Dates. │
│ │ A. Work requested is necessary to continuing operation of facilties│
│ 3 │ B. Date required to be met: │
│ │ 1. By use of overtime. │
│ │ 2. At expense of lower priority work. │
│ │ C. Feedback from shops and field maintenance will assure │
│ │ operations of meeting dates or permit timely renegotiation. │
├───────┼──────────────────────────────────────────────────────────────────────┤
│ │ ROUTINE │
│ │ ~~~~~~~ │
│ │Necessary work that can be planned and scheduled. │
│ │ A. Overtime is not authorized without special approval. │
│ │ B. Feedback to operations is necessary to coordinate work with │
│ 4 │ shutdowns, turnarounds, etc. │
│ │ C. Work to be planned and scheduled to optimize efficiency of │
│ │ effort and assure completion dates. │
│ │ D. Dates are to be met or renegotiated in sufficient time to │
│ │ accomidate requestor. │
├───────┼──────────────────────────────────────────────────────────────────────┤
│ │ CONTINGENCY │
│ │ ~~~~~~~~~~~ │
│ │Desired work that may be rescheduled or deferred to suit │
│ │availablity of work. │
│ 5 │ A. Work not essential to the safety or continuity of operations. │
│ │ B. No overtime authorized. │
│ │ C. Work may be planned and not scheduled. │
│ │ D. Resources will be used as available. │
│ │ E. Delay of completion will not necessarily result in priority │
│ │ being changed. │
└───────┴──────────────────────────────────────────────────────────────────────┘