Computerized predictive maintenance system and method

• US 7,895,047 B2
• Filed: 01/14/2009
• Issued: 02/22/2011
• Est. Priority Date: 10/17/2000
• Status: Expired due to Term

• Current Assignee: Accenture Global Services Limited (Accenture PLC)
• Original Assignee: Accenture Global Services Limited (Accenture PLC)
• Inventors: Garrow, Gary R., Newton, Charles P. III, Wetzer, Michael, Weir, Patrick E., West, David P. II
• Primary Examiner(s): Elisca; Pierre E
• Application Number:
  US12/353,408
• Publication Number:
  US 20090125277A1
• Time in Patent Office: 769 Days
• Field of Search: 705/1, 705/7
• US Class Current: 705/1.1
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 10/063 Operations research, analysis or management
• 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 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders
• CPC Class Codes: G06Q 10/0875 Itemisation or classification of parts, supplies or services, e.g. bill of materials
• CPC Class Codes: G06Q 10/1097 Task assignment
• CPC Class Codes: G06Q 10/20 Administration of product repair or maintenance
• CPC Class Codes: Y10S 707/99932 Access augmentation or optimizing
• CPC Class Codes: Y10S 707/99933 Query processing, i.e. searching
• CPC Class Codes: Y10S 707/99934 Query formulation, input preparation, or translation
• CPC Class Codes: Y10S 707/99943 Generating database or data structure, e.g. via user interface
• CPC Class Codes: Y10S 707/99945 Object-oriented database structure processing
• CPC Class Codes: Y10S 707/99952 Coherency, e.g. same view to multiple users
• CPC Class Codes: Y10S 707/99953 Recoverability

Abstract

A computerized system for performing predictive maintenance on an item of equipment includes a desired configuration database, an actual configuration database and a data processor. The data processor determines if an actual configuration complies with a desired configuration. The data processor determines an upgrade requirement for upgrading the actual configuration to the desired configuration if the actual configuration is noncompliant. The data processor further defines an interim solution that eliminates delay in the execution of the upgrade requirement on the item of equipment.

Claims

1. A computer-implemented method of performing predictive maintenance on an item of equipment, comprising:

establishing in a storage device a first database that stores a desired configuration of the item of equipment with at least one of an equipment identifier, a component identifier, or an assembly identifier based on a predictive maintenance target of the item of equipment;

wherein the predictive maintenance target includes at least one of a physical configuration objective, a functional configuration objective, a logical configuration objective, and an operational configuration objective;

wherein the functional configuration objective of the item is consistent with meeting a performance metric of a group of equipment;

establishing in the storage device a second database that stores an actual configuration of the item of equipment with at least one of the equipment identifier, the component identifier, or the assembly identifier, wherein establishing the second database comprises;

receiving through a communication interface actual configuration data resulting from inspection or servicing of the item of equipment; and

storing with a data processor the actual configuration data into the second database;

retrieving with the data processor from the second database through a data bus and evaluating a selected actual configuration of the item of equipment to determine if the selected actual configuration complies with the desired configuration; and

executing with the data processor instructions stored on the storage device, comprising;

subjecting items of the group of equipment to more frequent predictive maintenance than other items of the group of equipment or prematurely retiring the items from service in accordance with the performance metric;

generating with the data processor an upgrade requirement if the actual configuration is noncompliant and storing the upgrade requirement in a third database in the storage device; and

executing with the data processor a real-time procedure comprising;

changing the actual configuration, the desired configuration and the upgrade requirement with time;

maintaining the actual configuration and the desired configuration on a selected item of equipment valid for a limited duration; and

updating the actual configuration and the desired configuration prior to expiration of the limited duration to avoid an outdated configuration.

2. The method according to claim 1, wherein establishing the first database comprises defining the logical configuration objective as a decision to substitute a generally suitable replacement component for an existing component of the item, rather than repair the existing component.

3. The method according to claim 1, wherein establishing the first database comprises defining the logical configuration objective as a decision to repair an existing component, rather than substitute a generally suitable replacement component for an existing component of the item.

4. The method according to claim 1, wherein establishing the first database comprises defining the logical configuration objective as a decision to repair a component, rather than to replace the component in kind.

5. The method according to claim 1, wherein establishing the first database comprises defining the logical configuration objective as a decision to replace the component in kind, rather than repair a component.

6. The method according to claim 1, wherein establishing the first database comprises defining the operational configuration objective as a measured response of the item to at least one operating requirement and an associated operating environment.

7. The method according to claim 1, wherein establishing the first database comprises defining the operational configuration objective as a measured response of a component of the item to at least one operating requirement and an associated operating environment.

8. The method according to claim 1, wherein establishing the first database comprises defining the operational configuration objective as a measured response of a system of the item to at least one operating requirement and an associated operating environment.

9. The method according to claim 1, wherein establishing the first database comprises storing the desired configuration of redundant components to enhance the reliability of the item of equipment.

10. The method according to claim 1, wherein establishing the first database comprises storing the desired configuration of a self-healing system to enhance the reliability of the item of equipment.

11. A computer-implemented system for generating and executing with a data processor instruction for performing predictive maintenance on an item of equipment, the system comprising:

a storage device comprising;

a desired configuration database for storing a desired configuration of the equipment with at least one of an equipment identifier, a component identifier, or an assembly identifier based on a predictive maintenance target of the item of equipment;

wherein the predictive maintenance target includes at least one of a physical configuration objective, a functional configuration objective, a logical configuration objective, and an operational configuration objective;

wherein the functional configuration objective of the item is consistent with meeting a performance metric of a group of equipment;

an actual configuration database for storing an actual configuration of the equipment with at least one of the equipment identifier, the component identifier, or the assembly identifier based on an evaluation of the equipment; and

a data processor coupled to the storage device through a data bus and for receiving through a communication interface actual configuration data resulting from inspection or servicing of the item of equipment and storing the actual configuration data into the actual configuration database,

wherein the data processor executes data process instructions stored on the storage device, execution of the data process instructions comprising;

retrieving from the actual configuration database through the data bus a selected actual configuration;

evaluating the selected actual configuration to determine if the selected actual configuration complies with the desired configuration;

generating an upgrade requirement for upgrading the actual configuration to the desired configuration if the actual configuration is noncompliant; and

subjecting items of the group of equipment to more frequent predictive maintenance than other items of the group of equipment or prematurely retiring the items from service in accordance with the performance metric;

wherein the data processor further executes an interim solution instruction that covers time periods after a noncompliance with the desired configuration is detected and prior to placing the selected actual configuration in conformity with the desired configuration, thereby eliminating delay in the execution of the upgrade requirement on the item of equipment, the interim solution instruction further blocking usage of the item of equipment whose actual configuration does not comply with the desired configuration and prompting provisional operational training of human resource.

12. The system according to claim 11, wherein the logical configuration objective is defined as a decision to substitute a generally suitable replacement component for an existing component of the item, rather than repair the existing component.

13. The system according to claim 11, wherein the logical configuration objective is defined as a decision to repair an existing component, rather than substitute a generally suitable replacement component for an existing component of the item.

14. The system according to claim 11, wherein the logical configuration objective is defined as a decision to repair a component, rather than to replace the component in kind.

15. The system according to claim 11, wherein the logical configuration objective is defined as a decision to replace the component in kind, rather than repair a component.

16. The system according to claim 11, wherein the operational configuration objective is defined as a measured response of the item to at least one operating requirement and an associated operating environment.

17. The system according to claim 11, wherein the operational configuration objective is defined as a measured response of a component of the item to at least one operating requirement and an associated operating environment.

18. The system according to claim 11, wherein the operational configuration objective is defined as a measured response of a system of the item to at least one operating requirement and an associated operating environment.

19. The system according to claim 11, wherein the data processor generates the upgrade requirement when one of the physical configuration objective, the functional configuration objective, the logical configuration objective, and the operational configuration objective of the actual configuration is noncompliant with the desired configuration and when others of the physical configuration objective, the functional configuration objective, the logical configuration objective, and the operational configuration objective of the actual configuration is compliant with the desired configuration.

20. A computer program product, comprising a non-transitory computer usable medium having a computer readable program code embodied therein, that when executed by the computer, causes the computer to perform a method comprising:

establishing in a storage device a first database that stores a desired configuration of the item of equipment with at least one of an equipment identifier, a component identifier, or an assembly identifier based on a predictive maintenance target of the item of equipment;

wherein the predictive maintenance target includes at least one of a physical configuration objective, a functional configuration objective, a logical configuration objective, and an operational configuration objective;

wherein the functional configuration objective of the item is consistent with meeting a performance metric of a group of equipment;

establishing in the storage device a second database that stores an actual configuration of the item of equipment with at least one of the equipment identifier, the component identifier, or the assembly identifier, wherein establishing the second database comprises;

receiving through a communication interface actual configuration data resulting from inspection or servicing of the item of equipment; and

storing with a data processor the actual configuration data into the second database; and

retrieving with the data processor from the second database through a data bus and evaluating a selected actual configuration of the item of equipment to determine if the selected actual configuration complies with the desired configuration;

executing with the data processor instructions stored on the storage device, comprising;

subjecting items of the group of equipment to more frequent predictive maintenance than other items of the group of equipment or prematurely retiring the items from service in accordance with the performance metric;

generating with the data processor an upgrade requirement if the actual configuration is noncompliant and storing the upgrade requirement in a third database; and

executing with the data processor a real-time procedure comprising;

changing the actual configuration, the desired configuration and the upgrade requirement with time;

maintaining the actual configuration and the desired configuration on a selected item of equipment valid for a limited duration; and

updating the actual configuration and the desired configuration prior to expiration of the limited duration to avoid an outdated configuration.

21. A computer-implemented maintenance system for performing predictive maintenance on an item of equipment, comprising:

a storage device comprising;

a desired configuration database for storing a desired configuration of the item of equipment with at least one of an equipment identifier, a component identifier, or an assembly identifier and in communication with an engineering input/output device through a communication interface;

an actual configuration database for storing an actual configuration of the item of equipment with at least one of the equipment identifier, the component identifier, or the assembly identifier and in communication with a maintenance input/output device through the communication interface; and

a supervisory database for storing historical records of prior configuration alternations and in communication with a supervisory management input/output device through the communication interface; and

a data processor in communication with the storage device and operable to receive an actual configuration data input from the maintenance input/output device, wherein the actual configuration data input represents observed configuration data during or after an inspection or servicing of the item of equipment, the data processor further operable to;

update the actual configuration database in response to the actual configuration data input;

determine a resultant upgrade requirement by comparing the actual configuration data input with corresponding desired configuration data stored in the desired configuration database, wherein the resultant upgrade requirement identifies a component identifier of a component requiring updating and software instructions requiring modification, and the upgrade requirement further identifies a schedule of maintenance workers to perform maintenance on the component and the software instructions;

decide whether to execute the resultant upgrade requirement; and

upon deciding to execute the resultant upgrade requirement, transmit the resultant upgrade requirement to an external management system through an output communication interface;

wherein the data processor forgoes execution of the resultant upgrade requirement when an input from the engineering input/output device, the supervisory management input/output device, or both overrides the decision to execute the resultant upgrade requirement.