Automatic work order/parts order generation and tracking

• US 6,965,806 B2
• Filed: 02/28/2002
• Issued: 11/15/2005
• Est. Priority Date: 03/01/2001
• Status: Active Grant

• Current Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Original Assignee: Fisher-Rosemount Systems Incorporated (Emerson Electric Company)
• Inventors: Marschall, Lester (David), Eryurek, Evren, Hokeness, Scott Nels, Harris, Stuart
• Primary Examiner(s): Knight, Anthony
• Assistant Examiner(s): BARNES-BULLOCK, CRYSTAL JOY
• Application Number:
  US10/086,159
• Publication Number:
  US 20020169514A1
• Time in Patent Office: 1,356 Days
• Field of Search: 700/27, 700/52, 700/79, 700/81, 700/95, 700/96, 700/216, 702182-185, 702/188, 705 26- 29, 714/25, 714/46, 714 37- 39, 714 48- 49, 714/57
• US Class Current: 700/96
• CPC Class Codes: G05B 13/0275 using fuzzy logic only
• CPC Class Codes: G05B 13/028 using expert systems only
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 19/41875 characterised by quality surveillance of production
• CPC Class Codes: G05B 2219/31288 Archive collected data into history file
• CPC Class Codes: G05B 2219/32015 Optimize, process management, optimize production line
• CPC Class Codes: G05B 2219/32018 Adapt process as function of results of quality measuring until maximum quality
• CPC Class Codes: G05B 2219/32235 Sharing of data between process control and maintenance management computers
• CPC Class Codes: G05B 2219/32371 Predict failure time by analysing history fault logs of same machines in databases
• CPC Class Codes: G05B 23/0243 model based detection method, e.g. first-principles knowledge model
• CPC Class Codes: G05B 23/0294 Optimizing process, e.g. process efficiency, product quality
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders
• CPC Class Codes: G06Q 30/0633 Lists, e.g. purchase orders, compilation or processing
• CPC Class Codes: Y02P 80/10 Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier
• CPC Class Codes: Y02P 80/40 Minimising material used in manufacturing processes
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/80 Management or planning
• CPC Class Codes: Y10S 715/965 for process control and configuration

Abstract

A process control system uses an asset utilization expert to collect data or information pertaining to the assets of a process plant from various sources or functional areas of the plant including, for example, the process control functional areas, the maintenance functional areas and the business systems functional areas. This data and information is manipulated in a coordinated manner by tools, such as optimization and modeling tools and is redistributed to other areas or tools where it is used to perform overall better or more optimal control, maintenance and business activities. Information or data may be collected by maintenance functions pertaining to the health, variability, performance or utilization of a device, loop, unit, etc. and this information may then be sent to and displayed to a process operator or maintenance person to inform that person of a current or future problem. An application, such as a work order generation application, may automatically generate work orders, parts or supplies orders, etc. based on events occurring within the plant.

Claims

1. A method of automatically taking corrective measures within a process plant, wherein the process plant includes a plurality of devices, the method comprising:

receiving data pertaining to the status of a process plant device;

automatically generating an order in response to a detected problem with the process plant device, wherein the detected problem is based on the data pertaining to the status of the process plant device and the order relates to taking one or more corrective measures to solve the problem; and

communicating the order.

2. The method of claim 1, wherein receiving data comprises receiving diagnostic information pertaining to the process plant device.

3. The method of claim 1, wherein receiving data comprises receiving a maintenance request to service the process plant device.

4. The method of claim 1, wherein receiving data comprises receiving a notification of a current problem with the process plant device.

5. The method of claim 1, wherein receiving data comprises receiving a notification of a predicted future problem with the process plant device.

6. The method of claim 1, wherein receiving data comprises receiving a use index representative of the status of the process plant device.

7. The method of claim 6, wherein a maintenance system receives the use index and automatically generating an order comprises automatically generating a work order based on the use index.

8. The method of claim 7, wherein generating a work order comprises determining the one or more corrective measures to solve the problem.

9. The method of claim 7, further comprising displaying instructions for achieving a desired use index for the process plant device.

10. The method of claim 9, wherein displaying instructions for achieving a desired use index for the process plant device comprises displaying instructions representative of the one or more corrective measures to solve the problem.

11. The method of claim 1, further comprising determining the status of the process plant device based on at least one of process control data pertaining to the process plant device and maintenance data pertaining to the process plant device.

12. The method of claim 1, wherein generating an order comprises generating a work order for performing maintenance related to solving the problem with the process plant device, and communicating the order comprises communicating the work order to one or more maintenance personnel capable of performing the maintenance.

13. The method of claim 1, wherein generating an order comprises generating an order for a part related to solving the problem with the process plant device, and communicating the order comprises communicating the order for the part to a supplier of the part.

14. The method of claim 13, wherein generating an order comprises generating an order for a replacement device.

15. The method of claim 1, wherein communicating the order comprises communicating the order via the internet.

16. The method of claim 1, wherein communicating the order comprises communicating the order via a telephone communication link.

17. The method of claim 1, wherein communicating the order comprises communicating the order via a wireless communication link.

18. The method of claim 1, wherein generating an order comprises scheduling an order to be fulfilled prior to failure of the process plant device.

19. The method of claim 1, further comprising tracking the status of the order.

20. The method of claim 19, wherein tracking the status of the order comprises:

receiving data pertaining to a report regarding the order; and

receiving data pertaining to the date of the report.

21. The method of claim 20, wherein receiving data pertaining to a report comprises receiving data pertaining to the location of the order.

22. The method of claim 20, wherein receiving data pertaining to a report comprises receiving data pertaining to the status of the order.

23. The method of claim 1, wherein receiving data comprises receiving data pertaining to one of a field device and field equipment.

24. The method of claim 1, wherein receiving data comprises receiving data pertaining to the status of one of a two-wire device, a three-wire device, a four-wire device, a wireless device, a device having a processor, a variable speed driver, a controller, a multiplexer, rotating equipment, an actuator, power generation equipment, power distribution equipment, a transmitter, a sensor, a control system, a transceiver, a valve, a positioner, a switch, electrical equipment, a server, a hand held device, a pump, an I/O system, a smart field device, a non-smart field device, a HART protocol device, a Fieldbus protocol device, a PROFIBUS®

protocol device, a WORLDFIP®

protocol device, a Device-Net®

protocol device, a AS-Interface protocol device, a CAN protocol device, a TCP/IP protocol device, an Ethernet device, an internet-based device, and a network communication device.

46. The method of claim 1 wherein automatically generating an order comprises automatically generating an order in response to a particular detected problem with the process plant device, wherein the particular detected problem is based on the data pertaining to the status of the process plant device and the order includes corrective measures specific to solving the particular problem.

25. A system to be used in a process control environment for automatically taking corrective measures, wherein the process control environment includes a plurality of devices, the system comprising:

a computer readable memory;

a first routine stored on the computer readable memory and adapted to be executed on a processor to receive data pertaining to the status of a process plant device;

a second routine stored on the computer readable memory and adapted to be executed on a processor to automatically generate an order in response to a detected problem with the process plant device, wherein the order relates to taking one or more corrective measures to solve the problem;

a third routine stored on the computer readable memory and adapted to be executed on a processor to communicate the order.

26. The system of claim 25, wherein the first routine is adapted to receive diagnostic information pertaining to the process plant device.

27. The system of claim 25, wherein the first routine is adapted to receive a maintenance request to service the process plant device.

28. The system of claim 25, wherein the first routine is adapted to receive a notification of a current problem with the process plant device.

29. The system of claim 25, wherein the first routine is adapted to receive a notification of a predicted future problem with the process plant device.

30. The system of claim 25, wherein the first routine is adapted to receive a use index representative of the status of the process plant device.

31. The system of claim 25, wherein the second routine is adapted to generate a work order for performing maintenance related to solving the problem with the process plant device, and the third routine is adapted to communicate the work order to one or more maintenance personnel capable of performing the maintenance.

32. The system of claim 25, wherein the second routine is adapted to generate an order for a part related to solving the problem with the process plant device, and the third routine is adapted to communicate the order for the part to a supplier of the part.

33. The system of claim 32, wherein the second routine is adapted to generate an order for a replacement device.

34. The system of claim 25, wherein the third routine is adapted to communicate the via the internet.

35. The system of claim 25, wherein the third routine is adapted to communicate the order via a telephone communication link.

36. The system of claim 25, wherein the third routine is adapted to communicate the order via a wireless communication link.

37. The system of claim 25, wherein the second routine is adapted to schedule an order to be fulfilled prior to failure of the process plant device.

38. The system of claim 25, further comprising a fourth routine stored on the computer readable memory and adapted to be executed on a processor to track the status of the order.

39. The system of claim 38, wherein the fourth routine is adapted to receive data pertaining to a report regarding the order and to receive data pertaining to the date of the report.

40. The system of claim 39, wherein the fourth routine is adapted to receive data pertaining to the location of the order.

41. The system of claim 39, wherein the fourth routine is adapted to receive data pertaining to the status of the order.

42. The system of claim 38, further comprising a fifth routine stored on the computer readable memory and adapted to be executed on a processor to display tracking information relating to the status of the order.

43. The system of claim 25, further comprising a fourth routine stored on the computer readable memory and adapted to be executed on a processor to perform a business-to-business transaction to automatically place an order for a part.

44. The system of claim 25, wherein the first routine is adapted to receive data pertaining to one of a field device and field equipment.

45. The system of claim 25, wherein the first routine is adapted to receive data pertaining to the status of one of a two-wire device, a three-wire device, a four-wire device, a wireless device, a device having a processor, a variable speed driver, a controller, a multiplexer, rotating equipment, an actuator, power generation equipment, power distribution equipment, a transmitter, a sensor, a control system, a transceiver, a valve, a positioner, a switch, electrical equipment, a server, a hand held device, a pump, an I/O system, a smart field device, a non-smart field device, a HART protocol device, a Fieldbus protocol device, a PROFIBUS®

protocol device, a WORLDFIP®

protocol device, a Device-Net®

protocol device, a AS-Interface protocol device, a CAN protocol device, a TCP/IP protocol device, an Ethernet device, an internet-based device, and a network communication device.