Knowledge-based condition survey inspection (KBCSI) framework and procedure

• US 20060009935A1
• Filed: 07/09/2004
• Published: 01/12/2006
• Est. Priority Date: 07/09/2004
• Status: Active Grant

• Current Assignee: US Army Corps of Engineers (U.S. Department Of Defense)
• Original Assignee: US Army Corps of Engineers (U.S. Department Of Defense)
• Inventors: Grussing, Michael N., Uzarski, Donald R.
• Granted Patent: US 7,058,544 B2
• Time in Patent Office: Days
• US Class Current: 702/81
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling

Abstract

A knowledge-based condition survey inspection (KBSCI) framework and procedure for use with an engineering management system (EMS) that tailors types of condition survey inspections (CSIs) and inspection intervals to empirically-established life cycles of component-sections. Embodiments of the invention facilitate proactive life cycle management, scheduling appropriate types of CSIs only when needed. The frequency and type of inspection is tailored to items important to a facility manager, such as the importance to the operation of individual component-sections and their individual life cycle, not the overall life cycle of a system or facility. Further, additional useful information is available from the data collected to maintain embodiments of the KBCSI framework so that meaningful “What-If” analysis may be performed in support of decision makers. By tailoring CSIs to needs rather than an arbitrary inspection schedule designed to only catch deficiencies, significant life cycle cost savings are realized.

Claims

1. A method for tailoring inspections and maintenance of component-sections of facilities that may incorporate components and systems, at least one said component-section incorporated in at least one said component, said component sections having an established life cycle, comprising:

linking to at least one database of at least one engineering management system (EMS),

wherein said linking provides at least one identifier and at least one parameter for each said component-section;

establishing at least one type of condition survey inspection;

establishing at least one criterion for inspection of said component-sections during said life cycle,

wherein at least one said criterion may be established from data collected during said condition survey inspections;

establishing at least one component-section condition index (CSCI) having discrete values for said component-sections;

employing at least one algorithm to establish a relationship between said values of said condition index and time over said life cycle of each said component-section,

wherein said algorithm may use said data from at least one of said condition survey inspections and at least one of said criteria to at least partially establish said relationship, and

wherein said relationship may be displayed as a curve on a graph;

defining at least one zone within said relationship by applying at least one of said criteria,

wherein within each said zone, both said types of condition survey inspections and the frequency of conducting said condition survey inspections are optimized by at least applying said criteria; and

wherein said method enables said condition survey inspections to be tailored based on the life cycle of said component-section.

2. The method of claim 1 in which said criteria are selected from the group consisting essentially of:

facility usage importance, system usage importance, component-section usage importance, expected service life of at least said component-section, remaining service life (RSL) of said component-section, maintenance life of said component-section, remaining maintenance life (RML) of said component-section, rate of deterioration of said component-section, specific distress tracking of said component-section, condition zone within which said component lies, condition standards applied to said component-section, deterioration factor, CSCI gain, mission dependency index (MDI), and maximum timeframe between condition survey inspections.

3. The method of claim 1 in which said engineering management system is BUILDER™

.

4. The method of claim 1 in which said types of condition survey inspections are selected from the group consisting essentially of:

direct ratings, direct ratings with sampling, direct ratings without sampling, paint ratings, paint ratings with sampling, paint ratings without sampling, distress surveys, distress surveys with sampling, distress surveys without sampling, distress surveys with quantities, and combinations thereof.

5. The method of claim 1 in which said condition index has a range of 0-100.

6. The method of claim 1 in which five said zones are employed.

7. The method of claim 6 in which said five zones comprise:

an initial zone, a pre-sweet spot zone, a sweet spot zone, a post-sweet spot zone, and a dead zone,

wherein said sweet spot zone incorporates said sweet spot defined as a time interval in said life cycle when performing maintenance on said component-section is predicted to be optimal.

8. The method of claim 2 in which said rate of deterioration is determined at a given point in said life cycle by the slope of the tangent to said curve at said point.

9. The method of claim 2 further comprising applying said deterioration factor to determine if scheduling at least one said condition survey inspection may be warranted.

10. The method of claim 2 further comprising iterating said algorithm at least after maintenance has been performed on said component-section,

wherein performing said maintenance may result in altering at least one said criteria, said life cycle, said zones, and said curve.

11. The method of claim 10 further comprising applying said CSCI gain to modify any of said life cycle, said zones, and said curve.

12. The method of claim 1 further comprising assigning an optimal said type of condition survey inspection to each said zone.

13. The method of claim 1 further comprising rolling up said relationship into a condition index of a component of said facility that incorporates said component-section.

14. The method of claim 1 further comprising establishing objectives that may be accomplished by each said type of condition survey inspections.

15. The method of claim 14 in which said objectives are selected from the group consisting essentially of:

determining the current condition of a component-section and assigning a condition index;

determining a current roll-up condition index;

providing a condition history;

computing deterioration rates;

establishing and maintaining LC curves;

computing remaining maintenance life to establish the sweet spot;

determining scope of work for planning;

quantifying and refining work requirements;

establishing repair/replace criteria;

calculating remaining service life; and

performing post-work assessment.

16. A method for managing facilities that may incorporate systems, components and component-sections, at least one said component-section incorporated in at least one said component, said component sections having an established life cycle, comprising:

providing an engineering management system (EMS) incorporating at least one database;

linking to at least one said database,

wherein said linking provides at least one identifier and at least one parameter for each said component-section;

establishing at least one type of condition survey inspection;

establishing at least one criterion for inspection of said component-sections during said life cycle,

wherein at least one said criterion may be established from data collected during said condition survey inspections;

establishing at least one component-section condition index (CSCI) having discrete values for at least said component-sections;

employing at least one algorithm to establish a relationship between said values of said condition index and time over said life cycle of each said component-section,

wherein said algorithm may use said data from at least one of said condition survey inspections and at least one of said criteria to at least partially establish said relationship, and

wherein said relationship may be displayed as a curve on a graph;

defining at least one zone within said relationship by applying at least one of said criteria,

wherein within each said zone, both said types of condition survey inspections and the frequency of conducting said condition survey inspections are optimized by at least applying said criteria; and

rolling up said relationship into a condition index of at least a component of said facility that incorporates said component-section,

wherein said method enables said condition survey inspections to be tailored based on the life cycle of said component-section.

17. The method of claim 16 in which said criteria are selected from the group consisting essentially of:

facility usage importance, system usage importance, component-section usage importance, expected service life of at least said component-section, remaining service life (RSL) of said component-section, maintenance life of said component-section, remaining maintenance life (RML) of said component-section, rate of deterioration of said component-section, specific distress tracking of said component-section, condition zone within which said component lies, condition standards applied to said component-section, deterioration factor, CSCI gain, mission dependency index (MDI), and maximum timeframe between condition survey inspections.

18. The method of claim 16 in which said engineering management system is BUILDER™

.

19. The method of claim 16 in which said types of condition survey inspections are selected from the group consisting essentially of:

direct ratings, direct ratings with sampling, direct ratings without sampling, paint ratings, paint ratings with sampling, paint ratings without sampling, distress surveys, distress surveys with sampling, distress surveys without sampling, distress surveys with quantities, and combinations thereof.

20. The method of claim 16 in which said condition index has a range of 0-100.

21. The method of claim 16 in which five said zones are employed.

22. The method of claim 21 in which said five zones comprise:

an initial zone, a pre-sweet spot zone, a sweet spot zone, a post-sweet spot zone, and a dead zone,

wherein said sweet spot zone incorporates said sweet spot defined as a time interval in said life cycle when performing maintenance on said component-section is predicted to be optimal.

23. The method of claim 17 in which said rate of deterioration is determined at a given point in said life cycle by the slope of the tangent to said curve at said point.

24. The method of claim 17 further comprising applying said deterioration factor to determine if scheduling at least one said condition survey inspection may be warranted.

25. The method of claim 17 further comprising iterating said algorithm at least after maintenance has been performed on said component-section,

wherein performing said maintenance may result in altering at least one said criteria, said life cycle, said zones, and said curve.

26. The method of claim 25 further comprising applying said CSCI gain to modify any of said life cycle, said zones, and said curve.

27. The method of claim 16 further comprising assigning an optimal said type of condition survey inspection to each said zone.

28. The method of claim 16 further comprising establishing objectives that may be accomplished by each said type of condition survey inspections.

29. The method of claim 28 in which said objectives are selected from the group consisting essentially of:

determining the current condition of a component-section and assigning a condition index;

determining a current roll-up condition index;

providing a condition history;

computing deterioration rates;

establishing and maintaining LC curves;

computing remaining maintenance life to establish the sweet spot;

determining scope of work for planning;

quantifying and refining work requirements;

establishing repair/replace criteria;

calculating remaining service life; and

performing post-work assessment.

30. A knowledge-based condition survey inspection framework for use with an engineering management system (EMS) to manage maintenance of component-sections of components of a facility incorporating components and systems, comprising:

a range of discrete condition indexes, said indexes used to assign a rating of condition for said component-section;

a description of each of one or more types of condition survey inspection (CSI);

a list of objectives to be met in said managing;

a matrix listing applicability of each of said types of CSIs to said objectives;

a list of criteria for at least determining at least one optimum type of said CSI to use and for establishing at least one interval during which to schedule said optimum type of CSI;

data from at least one such CSI;

means for applying said criteria and said data such that at least one life cycle (LC) curve representing said condition index of said component-section versus time may be developed; and

a description of zones of interest to be applied to said LC curve to facilitate assigning a said optimum type of CSI within each said zone.

31. The framework of claim 30 further comprising means for linking said framework to at least one engineering management system (EMS).

32. The framework of claim 31 in which said EMS is BUILDER™

.

33. The framework of claim 30 in which said means for applying said criteria comprise at least one algorithm.