Predictive maintenance system

• US 7,457,763 B1
• Filed: 09/04/2001
• Issued: 11/25/2008
• Est. Priority Date: 09/04/2001
• Status: Active Grant

• Current Assignee: Accenture Global Services Limited (Accenture PLC)
• Original Assignee: Accenture Global Services GmbH (Accenture PLC)
• Inventors: Garrow, Gary R., Newton, Charles P. III, Wetzer, Michael, Weir, Patrick E., West, David P. II
• Primary Examiner(s): Sterrett; Jonathan G
• Application Number:
  US09/947,157
• Time in Patent Office: 2,639 Days
• Field of Search: 705/8, 705/7, 702/81
• US Class Current: 705/7.24
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 10/06311 Scheduling, planning or task assignment for a person or group
• CPC Class Codes: G06Q 10/06314 Calendaring for a resource
• CPC Class Codes: G06Q 10/06315 Needs-based resource requirements planning or analysis
• CPC Class Codes: G06Q 10/10 Office automation; Time management

Abstract

A method and system for maintaining an item of equipment supports the provision of predictive maintenance in a manner which eliminates or reduces downtime of the equipment. The method includes tracking performance data on the equipment or a particular component of the equipment. At least one required maintenance activity is predicted based upon the performance data with respect to a defined performance standard. Performance of the required maintenance activity is scheduled at a defined respective time based upon the prediction.

Claims

1. A predictive maintenance method for an item of equipment, the method comprising:

establishing a first business module as a first resultant business framework for supporting maintenance work on the item of equipment, the resultant business framework comprising at least three feature modules including;

a prediction module determining predictive maintenance as part of the maintenance work based on an actual discovery of a maintenance need from inspection of the equipment, estimation of the maintenance need from a current performance evaluation of the equipment, and a forecast of the maintenance need from historical performance evaluation of the equipment,

a resource availability module comprising temporal data and related geographic data of resources for performing prospective predictive maintenance activity; and

an integration module comprising a scheduler integrating the prediction module and the resource availability module;

selecting first core elements for the first business module required for performing the maintenance work on the item of equipment wherein the core elements comprise modular constituent parts of the first business module, and wherein desired features of the first business module determine the first core elements and define functions of the first core elements, the first core elements including;

a performance data manager in the prediction module managing storage and retrieval of performance standard data indicative of a measurable achievement of a required specific task of the maintenance work within a specified time limit; and

an availability data manager in the resource availability module managing storage and retrieval of availability data, the availability data including worker data, facility data, tool data and component data for performing the maintenance work;

organizing the first core elements into the first resultant business framework of a first provider of the maintenance work;

establishing an additional business module comprising additional core elements as an additional resultant business framework of an additional provider of the maintenance work;

integrating and linking the first core elements and the additional core elements across the first business module and the additional business module for allocation of human resources, test equipment, maintenance tools, components, infrastructure and a facility for performing the predictive maintenance included in the maintenance work; and

executing the established first business module by predicting with the prediction module, and as part of the maintenance work, a first required maintenance activity on a first component and a second required maintenance activity on a second component by;

prior to performing either of the first and second required maintenance activities, identifying the first component and the second component as suspect components of the item of equipment when first component performance data, received from an equipment sensor, and second component performance data, input at a prediction module user interface, deviate from a defined performance standard;

flagging the first component and the second component of the item of the equipment with a suspect status;

clearing the suspect status of the first component in response to an acknowledgement input at the prediction module user interface prior to initiating performance of the first required maintenance activity;

determining a preliminary maintenance schedule for performing the second required maintenance activity on the second equipment; and

wherein executing the established business module further comprises scheduling performance of the second required maintenance activity for the item of the equipment with the scheduler by;

determining a first revision to the preliminary maintenance schedule, the first revision specifying substitution of an alternate component for the second component of the item of equipment; and

generating a resultant maintenance schedule based on the preliminary maintenance schedule and the first revision.

2. The method according to claim 1 further comprising defining the first and second required maintenance activities in accordance with differential levels of maintenance within a hierarchical scheme of maintenance levels, wherein the differential levels of the hierarchical scheme comprise different priority levels for performing the first and second required maintenance activities and organizing the resultant maintenance plan as a temporal sequence of ordered maintenance activities.

3. The method according to claim 1 further comprising:

parsing data in the resultant maintenance schedule to obtain a determination of whether or not to generate a purchase order; and

when the purchase order should be generated, generating the purchase order to obtain requisite components for facilitating execution of the resultant maintenance schedule.

4. The method according to claim 1 further comprising inspecting the equipment at an interval and scheduling supplemental maintenance associated with a discovered deficiency during inspection.

5. The method according to claim 1 further comprising defining the first component based on its relationship to the second component and the context of its use.

6. The method according to claim 1 wherein establishing the first business module further comprises:

establishing a multidimensional configuration manager, the multidimensional configuration manager defining a component content for the item of equipment, an integration of the component content supported by a functional descriptor, a logical descriptor, a physical descriptor, or a combination thereof.

7. The method according to claim 1 wherein executing the established first business module further comprises forecasting, with the prediction module, an additional maintenance activity based on historical performance evaluation of the item of equipment.

8. The method according to claim 1 wherein establishing the first business module further comprises:

establishing a nomenclature manager establishing a universal nomenclature definition applicable to at least one of the components, an equipment, a system, an assembly of components, or a combination thereof to support the exchange of data associated with the nomenclature definition.

9. The method according to claim 1 wherein establishing the first business module further comprises:

establishing a search engine for querying a database containing components associated with corresponding universal nomenclature descriptors.

10. The method according to claim 1 wherein establishing the first business module further comprises:

establishing an activity-cost manager tracking the costs for maintaining the components, an assembly of components, the item of equipment, or a combination thereof.

14. The method according to claim 1, wherein the resource availability module determines a temporal and geographic correspondence of the resources required for the performance of the second required maintenance activity;

and

wherein generating the resultant maintenance schedule further comprises;

generating the resultant maintenance schedule based on the preliminary maintenance schedule, the first revision and the temporal and geographical correspondence.

11. A computer architecture for implementing a predictive maintenance system for an item of equipment, comprising:

a first business module as a first resultant business framework for supporting maintenance work on the item of equipment, the resultant business framework comprising at least three feature modules including;

a prediction module operable to determine predictive maintenance as part of the maintenance work based on an actual discovery of a maintenance need from inspection of the equipment, estimation of the maintenance need from a current performance evaluation of the equipment, and a forecast of the maintenance need from historical performance evaluation of the equipment;

a resource availability module comprising temporal data and related geographic data of resources for performing prospective predictive maintenance activity; and

an integration module comprising a scheduler that integrates the prediction module and the resource availability module;

first core elements for the first business module required for performing the maintenance work on the item of equipment wherein the core elements comprise modular constituent parts of the first business module, and wherein desired features of the first business module determine the first core elements and define functions of the first core elements, the first core elements organized into the first resultant business framework of a first provider of the maintenance work, the first core elements including;

a performance data manager in the prediction module and operable to manage storage and retrieval of performance standard data indicative of a measurable achievement of a required specific task of the maintenance work within a specified time limit; and

an availability data manager in the resource availability module and operable to manage storage and retrieval of availability data, the availability data including worker data, facility data, tool data and component data for performing the maintenance work;

an additional business module comprising additional core elements as an additional resultant business framework of an additional provider of the maintenance work;

a data processing system operable to;

integrate and link the first core elements and the additional core elements across the first business module and the additional business module for allocation of human resources, test equipment, maintenance tools, components, infrastructure and a facility for performing the predictive maintenance included in the maintenance work; and

execute the first business module by executing the prediction module to predict a first required maintenance activity on a first component and a second required maintenance activity on a second component,

wherein the prediction module is further operable to;

identify, prior to performing either of the first and second required maintenance activities, the first component and the second component as suspect components of the item of equipment when the first component performance data, received from an equipment sensor, and the second component performance data, input at a prediction module user interface, deviate from a defined performance standard;

flag the first and second components with a suspect status,

clear the suspect status of the first component in response to an acknowledgement input at the prediction module user interface prior to initiating performance of the first required maintenance activity for the first component, and

determine a preliminary maintenance schedule for performing the second required maintenance activity on the second component; and

wherein the data processing system is further operable to execute the first business module by executing the scheduler, the scheduler operable to;

accept input from the prediction module and schedule the second required maintenance activity for the second component of the item of equipment in a resultant maintenance schedule;

determine a first revision to the preliminary maintenance schedule, the first revision specifying substitution of an alternate component for the second component of the item of equipment; and

,

generate the resultant maintenance schedule based on the preliminary maintenance schedule and the first revision.

12. The computer architecture according to claim 11, wherein the first and second required maintenance activities correspond to differential levels of maintenance within a hierarchical scheme of maintenance levels, and wherein the differential levels of the hierarchical scheme represent different priority levels for performing the first and second required maintenance activities and organizing the resultant maintenance plan as a temporal sequence of ordered maintenance activities.

13. The computer architecture according to claim 11, wherein the first business module further comprises an acquisition module configured to parse data contained in the resultant maintenance schedule to obtain a determination of whether or not to generate a purchase order, wherein the acquisition module is further configured to generate the purchase order to obtain requisite components for facilitating execution of the resultant maintenance schedule.

15. The computer architecture according to claim 11, wherein the resource availability module comprises material data that specifies a temporal and geographic correspondence of the resources required for the performance of the second required maintenance activity;

and

wherein the scheduler is further operable to generate the resultant maintenance schedule based on the preliminary maintenance schedule, the first revision, and the temporal and geographic correspondence.