Maintenance interval determination and optimization tool and method

• US 8,401,726 B2
• Filed: 07/20/2006
• Issued: 03/19/2013
• Est. Priority Date: 07/20/2006
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Bouvier, Ken D., Fredgren, Brian C., Scholz, Fritz, Altschul, Roberto E., Song, Shuguang
• Primary Examiner(s): Tarcza, Thomas
• Assistant Examiner(s): MUSTAFA, IMRAN K
• Application Number:
  US11/489,864
• Publication Number:
  US 20080021604A1
• Time in Patent Office: 2,434 Days
• Field of Search: 701/29, 701/30, 701 291- 299, 701 301- 309, 340/457.4
• US Class Current: 701/29.1
• CPC Class Codes: G06Q 10/00 Administration; Management
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G07C 5/006 Indicating maintenance

Abstract

A Maintenance Interval Determination and Optimization Tool (MIDOT) provides optimized maintenance schedules for performing maintenance tasks on one or more components or systems based on component survival functions and economic analysis of non-safety tasks associated with maintenance schedules. MIDOT is used for specified platforms such as aircrafts. The MIDOT filters maintenance history data, uses a statistical analysis to predict likely maintenance needs, and performs an economic analysis to optimize aircraft maintenance schedules. Specifically, the MIDOT calculates component survival probability, based on the specific usage of one or more related components within the platform and determines an optimal maintenance task interval to perform a maintenance task associated with the one or more related components.

Claims

1. A method of using a maintenance interval determination and optimization tool (MIDOT) for optimizing a maintenance schedule associated with commercial fleet vehicles comprising the steps of:

collecting historical maintenance data from one or more components within a platform, said platform comprising commercial fleet vehicles, said one or more components comprising vehicle components selected from an entire vehicle in addition to said vehicle engine;

associating a maintenance task with the one or more components;

determining an optimal maintenance task interval to perform the associated maintenance task on the one or more components, said optimal maintenance task interval determined according to statistical analysis that determines a survival probability function including selected confidence bounds, said survival probability function comprising a plotted Weibull distribution of associated component lifetimes, said component lifetimes derived from specific actual usage of each of said one or more components, said maintenance task interval selected within said confidence bounds to equal a survival probability threshold of the one or more components surviving a specified time, said survivable probability function derived from said historical maintenance data, said historical maintenance data comprising a same associated maintenance task or cause associated with the one or more components, the step of determining of an optimal maintenance task interval to perform the associated maintenance task on the one or more components including the steps of;

extracting component maintenance data associated with the one or more components from a component maintenance database, the step of extracting the component data including the steps of;

querying a component maintenance database to extract component maintenance data including removal data associated with removal events of the one or more components; and

exporting the extracted query results to a second component maintenance database;

processing the component maintenance data to remove data that is not relevant to the associated maintenance task, the step of processing the component data including the steps of;

using the exported extracted query results to form a second data set;

identifying data related to removal of each of the one or more components to service another platform; and

identifying data related to removal of components that are removed due to non-maintenance related schedules such as service directives; and

analyzing the component maintenance data to determine said optimal maintenance task interval that meets a specific survival function percentage comprising said survival probability function, the step of analyzing the data including the steps of;

determining associated component lifetimes for each of the one or more components from the second data set;

plotting the associated component lifetimes in said Weibull distribution of the second data set to form plotted component lifetime data points;

performing a Weibull analysis on the plotted component lifetime data points;

determining said optimal maintenance interval for each maintenance task to be performed on the one or more related components; and

comparing the optimal maintenance interval with an existing maintenance interval to determine if use of the optimal maintenance interval is economically feasible for a non-safety task; and

incorporating said optimal maintenance task interval in said maintenance schedule associated with said commercial fleet vehicles.

2. The method of claim 1, wherein the one or more components are related components that define an electro-mechanical system of components.

3. The method of claim 1, wherein the platform is an aircraft.

4. The method of claim 1, wherein the step of associating a maintenance task comprises the step of:

selecting the maintenance task from a non-safety task performed for economic reasons to reduce operational interruptions.

5. The method of claim 1, further comprising the step of:

performing an economic analysis to determine whether costs associated with performing the associated maintenance task according to the optimal maintenance task interval for the one or more components is feasible, wherein the associated maintenance task is a non-safety task.

6. The method of claim 1 further comprising determining that the one or more components perform a similar form, fit, and function on another platform.

7. The method of claim 1, wherein the step of analyzing the component maintenance data comprises the step of:

identifying the optimal maintenance task interval based on said specific component survival function percentage.

8. The method of claim 1, wherein the step of processing the maintenance data further comprises the steps of:

removing non-event data from the component maintenance data, wherein the non-event data includes data relating to events including removal of one or more related components that did not fix a complaint associated with the one or more related components or was not relevant to the associated complaint.

9. The method of claim 1, further comprising the step of:

performing an economic analysis to evaluate associated costs and benefits with the optimal maintenance task interval.

10. The method of claim 6, further comprising determining that there is a related non-safety task associated with similarly situated one or more components on the other platform and that the related non-safety task has a same failure cause as the one or more components subject to the determination of the optimal maintenance task interval, the component maintenance database includes data associated with the other platform.

11. The method of claim 1, further comprising determining that the one or more components do not exist on another platform, but perform a similar form, fit, and function to improved one or more components on the other platform.

12. The method of claim 11, further comprising determining that there is a related non-safety task associated with similarly situated one or more components on the other platform and that the related non-safety task has a same failure cause as the one or more components subject to the determination of the optimal maintenance task interval, the component maintenance database being associated with the other platform.

13. A method of using a maintenance interval determination and optimization tool for optimizing a maintenance schedule associated with commercial fleet vehicles comprising the steps of:

collecting historical maintenance data from one or more components within a platform, said platform comprising commercial fleet vehicles, said one or more components comprising vehicle components selected from an entire vehicle in addition to said vehicle engine;

selecting a maintenance task associated with said one or more components;

performing a statistical analysis on one or more components to determine a suggested maintenance task interval associated with the maintenance task, said statistical analysis determining a survival probability function including user selected confidence bounds, said survival probability function comprising a plotted Weibull distribution of associated component lifetimes said component lifetimes derived from specific actual usage of each of said one or more components, said maintenance task interval selected within said confidence bounds to equal a survival probability threshold of the one or more components surviving a specified time, said survivable probability function derived from said historical maintenance data, said historical maintenance data comprising a same maintenance task or cause associated with the one or more components, the step of determining of an optimal maintenance task interval to perform the associated maintenance task on the one or more components including the steps of;

extracting component maintenance data associated with the one or more components from a component maintenance database, the step of extracting the component data including the steps of;

querying a component maintenance database to extract component maintenance data including removal data associated with removal events of the one or more components; and

exporting the extracted query results to a second component maintenance database;

processing the component maintenance data to remove data that is not relevant to the associated maintenance task, the step of processing the component data including the steps of;

using the exported extracted query results to form a second data set;

identifying data related to removal of each of the one or more components to service another platform; and

identifying data related to removal of components that are removed due to non-maintenance related schedules such as service directives; and

analyzing the component maintenance data to determine said optimal maintenance task interval that meets a specific survival function percentage comprising said survival probability function, the step of analyzing the data including the steps of;

determining associated component lifetimes for each of the one or more components from the second data set;

plotting the associated component lifetimes in said Weibull distribution of the second data set to form plotted component lifetime data points;

performing a Weibull analysis on the plotted component lifetime data points;

determining said optimal maintenance interval for each maintenance task to be performed on the one or more related components; and

comparing the optimal maintenance interval with an existing maintenance interval to determine if use of the optimal maintenance interval is economically feasible for a non-safety task;

performing an economic analysis to determine whether costs associated with performing the associated maintenance task according to the suggested maintenance task interval is feasible if the maintenance task is a non-safety task; and

incorporating said optimal maintenance task interval in said maintenance schedule associated with said commercial fleet vehicles.

14. The method of claim 13, wherein the step of performing a statistical analysis on one or more components to determine a suggested maintenance task interval associated with the maintenance task comprises:

determining that the one or more components have similar tasks for components existing on another platform having a same associated maintenance cause.

15. The method of claim 14, wherein the component maintenance database includes data associated with the other platform.

16. A maintenance interval determination and optimization software tool comprising programmed instructions stored in computer readable memory for optimizing maintenance schedules associated with commercial fleet vehicles comprising:

a maintenance task selection module that operates to associate one or more components associated with a platform with a maintenance task, said one or more components comprising vehicle components selected from an entire vehicle in addition to said vehicle engine; and

a statistical calculation module comprising programmed instructions stored in computer readable memory, said programmed instructions performing a statistical analysis based on historical maintenance data comprising said one or more components or based on historical maintenance data comprising similar tasks for components existing on another platform having a same associated maintenance cause, said statistical calculation module comprising programmed instructions to determine a suggested maintenance task interval associated with the maintenance task, said statistical calculation module comprising programmed instructions to determine a survival probability function including user-selected confidence bounds, said survival probability function comprising a plotted Weibull distribution of associated component lifetimes, said associated component lifetimes derived from specific actual usage of each of said one or more components, said suggested maintenance task interval selected within said confidence bounds to equal a survival probability threshold, said survivable probability function derived from said historical maintenance data.

17. The maintenance interval determination and optimization tool of claim 16, further comprising:

an economic analysis module comprising programmed instructions stored in computer readable memory, said programmed instructions performing an economic analysis to determine whether costs associated with performing the associated maintenance task according to the suggested maintenance interval for the one or more components is feasible if the maintenance task is a non-safety task.