Note: Descriptions are shown in the official language in which they were submitted.
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lVkETHOD AND SYSTEM FOR MANAGING CONFIGURATION OF
MECHANICAL EQUIPMENT
REFERENCE TO EARLIER FILED APPLICATION
The present application claims the benefit of U.S. Application Serial
No.09/690,793 filed October 17, 2000, entitled "CONFIGURING
MECI-IANICAL EQUIPMENT," which is incorporated by reference herein.
FIELD OF INVENTION
This invention relates to a method and system for managing configurations
of mechanical equipment.
BACKGROUND OF THE INVENTION
Mechanical equipment refers to a machine or machinery that is formed of a
defined arrangement of multiple components. A component means a component,
a sub-component, an assembly, a system, or any other part of an item of
equipment. A component may include, but need not include, one or more sub-
components. An assembly may comprise a group of components that are
integrated together. A component is not limited to mechanical elements and is
broadly defined to include an electrical assembly, an electrical system, an
electronic system, a computer controller, software, or the like. Mechanical
equipment includes heavy equipment and capital-intensive equipment that is
movable or fixed. Mobile mechanical equipment includes airplanes, busses,
locomotives, ships, cranes, heavy trucks, earth-moving equipment, or the like.
Fixed mechanical equipment includes electrical power generators, industrial
presses, manufacturing equipment, or the like.
A~configuration defines the identity of the components (e.g., parts), a
specification of the components, and the relationship among the arrangement of
components of the mechanical equipment, among other things. Because some
components are interchangeable with substitutes, the configuration of
mechanical
equipment may vary throughout a life span of the mechanical equipment as
equipment-related work (e.g., maintenance, repair, or overhaul work) is
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performed. A maintenance activity or a maintenance task refers to at least one
of
maintenance, repair and overhaul of an item of equipment or a component of the
item. The configuration of mechanical equipment may change because of a
revision of product definitions or a review (e.g., a financial and performance
review) of the mechanical equipment. Further, even during the manufacturing
process, the manufacturer of the mechanical equipment may substitute different
components (e.g., parts) from different suppliers to customize the mechanical
equipment, to meet a certain technical specifications for the mechanical
equipment, or to save manufacturing costs on the mechanical equipment. For
example, the manufacturer may change technical specifications of mechanical
equipment to rectify manufacturing anomalies or to facilitate more reliable
production. Thus, standard as-built documentation on the mechanical equipment
may contain erroneous information on the configuration of the equipment.
Maintenance, overhaul and repair personnel may keep few records of the
actual configuration of the equipment because of over-reliance on the
manufacturer's specifications, manuals, and as-built documentation. Even if
configuration records are available, the records may be difficult to use or
access.
Thus, a need exists for promoting the maintenance of accurate records on
equipment-related work with ready access to maintenance, overhaul and repair
personnel.
In the context of an airplane as the mechanical equipment, the airplane may
be viewed as a member of a fleet subject to the fleet specifications in
general
manuals, rather than a unique configuration. If generalizations from the fleet
specifications are applied to an airplane, the generalization may not apply
because
of changes in the configuration made during maintenance (e.g., maintenance,
repair or overhaul) or earlier manufacturing changes. While the practical
experience of the mechanic or technician may overcome the informational gap
between the documentation and the actual configuration, such practical
experience
is often communicated inefficiently by word of mouth and documentation may be
unavailable. Moreover, repair and maintenance may become more costly where
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the mechanic or technician needs to figure out the implications of departures
from
expected or wrongly documented configurations on an ad-hoc basis.
The operator or owner of the mechanical equipment may operate
equipment with a sub-optimal configuration that does not comply with a desired
technical specification because of a lack of adequate procedures for
identification
of the desired technical specification and tracking compliance with the
desired
technical specification. For example, a typical performance guarantee or
warranty
for an airplane, as the mechanical equipment, may cover the number of
landings/takeoffs, engine hours, and general availability of flight readiness
of the
aircraft. However, an operator or an owner of an aircraft may fail to enforce
the
warranty or performance guarantee against the manufacturer because the lack of
adequate record-keeping and monitoring of the actual performance of the
aircraft
that are necessary to demonstrate a performance deficiency. Thus, a need
exists
for a procedure that facilitates monitoring of compliance with a desired
technical
performance objective for the mechanical equipment.
In regulated industries, such as the airline industry, the noncompliance with
a desired technical specification may represent a violation of a regulatory
standard,
which can subject the operator or owner of the mechanical equipment to
economic
penalties. Moreover, noncompliance with a configuration may pose a serious
threat to the safety of passengers aboard a noncompliant aircraft. Thus, a
need
exists for facilitating compliance of a configuration of mechanical equipment
with
applicable safety requirements on a timely basis.
Some products, especially technologically and physically complex
products, are the end result of the development of several dimensions of
configuration for that product to perform a task based on a set of product
design
principles. Each of these configurations has an impact on the ability to
properly
maintain, repair, or overhaul the end item, or to create a plan or schedule
for such
efforts. Product design principles, which generate multiple configurations,
typically focus on assuring the performance by the product of a task, or set
of
tasks, within acceptable levels of risk. The satisfaction of all of those
performance
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risks leads to the definition of a functional configuration for the end item
that can
trace product features back to a functional need expressed for the product.
There are also significant product design risks that must be dealt with and
successfully resolved after the functional configuration is known, and which
result
in the definition of additional types of configurations for the equipment.
Risks of
this type include levels and duration of product task performance, cost of
production of the end item, obsolescence of the end item relative to the task,
or
risks specific to the industry in which the end item is used. Safety of
operation,
the chance and cost of catastrophic failure, etc, and each type of risk must
be fully
10, reconciled. The reconciliation of these inter-linked risks results in
various
configuration decisions. Thus, a need exists for facilitating compliance of
multiple configurations of mechanical equipment.
BRIEF SUMMARY OF THE INVENTION
Iri accordance with the invention, a method and system of managing a
configuration of mechanical equipment provides a structured procedure for
managing information on parameters of the mechanical equipment to facilitate
the
maintenance of safety, legal compliance, performance, and reliability of the
mechanical equipment. A desired configuration of the mechanical equipment is
defined based on a design objective, such as safety, reliability, performance,
or
any combination of the foregoing objectives. An actual configuration of the
mechanical equipment is determined based on an evaluation of the physical
condition of the mechanical equipment. Upgrade requirements are planned for
upgrading the actual configuration to the desired configuration if the actual
configuration is noncompliant with the desired configuration.
A database of configurations is maintained of mechanical equipment. An
actual configuration database includes a physical configuration database and
an
operational configuration database. A desired configuration database includes
a
logical configuration database and a functional configuration database. The
functional configuration database is established to store functional
information
about an end item and internal components of the end item. The logical
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configuration database is established that corresponds to the functional
configuration database. The physical configuration database is established to
store
physical information about the end item. The operational configuration
database
is established to store operational information about the end item. The
database of
configurations of mechanical equipment is maintained in accordance with the
functional configuration database, the logical configuration database, the
physical
configuration database and the operational configuration database.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a system for managing a configuration of
mechanical equipment in accordance with the invention.
FIG. 2 is a block diagram of an illustrative hierarchical data structure for
organizing the configuration data in accordance with the invention.
FIG. 3 is a flow chart of a method for managing the configuration in
accordance with the invention.
FIG. 4 is a block diagram of an alternate embodiment of a system for
managing a configuration of mechanical equipment in accordance with the
invention.
FIG. 5 is a graph that shows multiple configurations per each mechanical
equipment over time in accordance with the invention.
FIG. 6 is a block diagram of an illustrative hierarchical data structure for
organizing functional configuration data and logical configuration data in
accordance with the invention.
FIG. 7 is a block diagram of an illustrative hierarchical data structure for
organizing physical configuration data and operational configuration data in
accordance with the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The definitions set forth in the background apply to the entire specification.
In accordance with the invention, FIG. 1 shows a system 11 for managing a
configuration of mechanical equipment. A maintenance input/output device 10,
an
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engineering input/output device 12, and a supervisory input/output device 14
are
coupled to a data processing system 16 to permit the input of data into the
data
processing system 16. The data processing system 16 may be coupled to a
materials management system 36 to permit the output of data to the materials
management system 36. A material includes raw materials, a consumable, a
component, a provision, or other equipment-related resources related to the
performance of a maintenance activity. Further, the data processing system 16
may be coupled to maintenance management system 42 to provide data for
operation of the maintenance management system 42.
The data processing system 16 includes a storage device 20 coupled to a
data processor 30 and communications interfaces 18 coupled to the data
processor
30 via a databus 34. The databus 34 and communications interfaces 18 provide
access of the input/output devices (10, 12 and 14) to one or more databases
(22,
24, 26 and 28). The arrows interconnecting the components of the data
processing
system 16 represent data flow over the databus 34. Although only one databus
is
shown in FIG. 1, in other embodiments multiple databuses and/or mufti-
processor
computer architecture may be used to practice the invention.
The storage device 20 refers to any computer storage mechanism that
supports a magnetic storage medium, an optical storage medium, an electronic
storage medium, or any other suitable storage medium. The storage device 20
may contain an actual configuration database 22, a desired configuration
database
24, a upgrade requirements database 26, and a supervisory/ historical database
28.
The data processing system 16 supports data storage, retrieval, and queries of
the
databases stored in the storage device 20.
The maintenance input/output device 10 is coupled to the actual
configuration database 22 via a communications interface 18. The engineering
input/output device 12 is coupled to the desired configuration database 24 via
a
communications interface 18. The supervisory input/output device 14 is coupled
to the supervisory database 28 via a communications interface 18. In one
embodiment, the maintenance input/output device 10, the engineering
input/output
device 12, and the supervisory input/output device 14 may represent computer
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work stations or other data input/output devices. In another embodiment, the
maintenance input/output device 10 may comprise a monitor for manually or
automatically monitoring the operational performance or longevity (e.g., time
and/or operational cycle compliance) of a part, an assembly, or the entire
mechanical equipment. For example, the monitor may provide a report of
assembly longevity data or part longevity data for storage in the actual
configuration database 22.
The actual configuration database 22 and the desired configuration
database 24 provide input configuration data to the data processor 30. The
data
processor 30 outputs upgrade requirements data to the upgrade requirements
database 26 and the supervisory database 28 based on the input of the
configuration data. The supervisory database 28 may include historical
configuration data on previous configurations and associated performance of
previous .configurations of the mechanical equipment. The upgrade requirements
database 26 is coupled to an output communications interface 32.
The communications interfaces 18 may comprise buffer memory coupled
to transceivers. The communications interfaces 18 may support a parallel port,
a
serial port, or another computer port configuration.
The output communications interface 32 may comprise buffer 38 memory
coupled to a transceiver 40. The output communications interface 32 is adapted
to
transmit upgrade requirements data from the upgrade requirements database 26
to
one or more of the following devices: (1) the materials management system/
purchasing system 36, (2) maintenance management system 42, and any other
procurement or enterprise resource planning system. For example, the output
communications interface 32 may contain a software interface, a hardware
interface, or both to facilitate the proper exchange of information with the
materials management system 36, the maintenance management system 42, a
purchasing system, or an enterprise resource planning system.
The desired configuration database 24 contains desired configuration data
on the mechanical equipment. The desired configuration data contains an
equipment identifier (e.g., tail number of an airplane) that identifies the
entire
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mechanical equipment, a part identifier that identifies a part of the
mechanical
equipment, an assembly identifier that identifies an assembly of parts of the
equipment, a specification description that describes the specification of a
part,
and a relationship description that describes the relationship of a part to
the
mechanical equipment or a subassembly thereof. For example, the relationship
description may include the mounting position of a part on the mechanical
equipment. In one embodiment, the desired configuration database 24 may
include operating restrictions on the mechanical equipment because of the
presence of a particular part or a particular arrangement of parts of the
mechanical
equipment.
The actual configuration database 22 contains actual configuration data on
the mechanical equipment that reflects an actual or present status of the
mechanical equipment. The actual configuration data includes an equipment
identifier (e.g., tail number of an airplane) that identifies the entire
mechanical
equipment, a part identifier that identifies a part of the mechanical
equipment, an
assembly identifier that identifies an assembly or group of parts of the
equipment,
a specification description that describes the specification of the part, and
a
relationship description that describes the relationship of a part to the
mechanical
equipment or a subassembly thereof. For example, the relationship description
may include the mounting position of a part on the mechanical equipment. In
one
embodiment, the actual configuration database 22 may include operating
restrictions on the mechanical equipment because of the presence of a
particular
part or arrangement of particular parts on the mechanical equipment.
The contents of the actual configuration database 22, the desired
configuration database 24, and the upgrade requirements database 26 may vary
with time. Accordingly, configuration data on a particular mechanical
equipment
may only remain valid for a limited duration. Upon or before expiration of the
duraiion,~~the configuration is preferably updated. If the contents of the
databases
are updated with sufficient frequency to avoid outdated configuration data,
the
update procedure may be referred to as a real-time procedure. The real-time
procedure seeks to minimize inaccuracy of the configuration data by reflecting
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changes to the actual configuration of the mechanical equipment as the changes
occur with a minimal lag time thereafter. Changes to the actual mechanical
equipment may be necessary or proper to facilitate improvement of the actual
configuration. Thus, the data processing system 16 permits maintenance
activities
(e.g., maintenance, overhaul or repair) to be coordinated in real time on an
ongoing basis with the latest actual configuration data and the latest upgrade
requirements.
A' maintenance worker, such as a technician or a mechanic who is
responsible for maintaining or repairing the mechanical equipment, enters
actual
configuration data into the actual configuration database 22 during or after
an
inspection or servicing of the mechanical equipment. The inspection may
involve
a visual inspection, a physical inspection, a mechanical test, an electrical
test,
disassembly of portions of the mechanical equipment, or other activities that
might
uncover defects or nonconformities with respect to the desired configuration.
The
data processing system 16 updates the actual configuration data in the actual
configuration database 22 as soon as possible after the inspection or the
servicing
of the mechanical equipment to maintain the accuracy of the actual
configuration
database 22. For example, the maintenance input/output device 10 may be a
portable electronic device that is equipped to establish a wireless
communications
link or otherwise communicate with the data processing system 16.
The data processor 30 compares the actual configuration to the desired
configuration. The difference between the actual configuration and the desired
configuration may be referred to as the upgrade requirement. The upgrade
requirement defines the departure of the actual configuration from the desired
configuration and indicates the necessary actions to bring the mechanical
equipment into conformity with the desired configuration. The data processor
30
determines the upgrade requirement. The data processor 30 may express the
upgrade requirement in terms of (1) a component requirement (e.g., part,
assembly
or subassembly requirement) and (2) a human resource requirement that is
required to bring the actual configuration in conformity with the desired
configuration. The upgrade requirements may contain part identifiers of old
parts
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that require updating of a particular mechanical equipment to gain compliance
with the desired configuration. The component requirement is not limited to
electrical' or mechanical hardware. For example, the component requirement may
include modifications of software features and software instructions that are
associated with or integral to the functioning of the mechanical equipment.
The
human resource requirement may include the scheduling of one or more
maintenance workers (e.g., technicians and mechanics) to install, repair,
adjust,
reconfigure, replace or otherwise perform a service associated with the
component
requirement for the mechanical equipment.
The data processor 30 may define an interim solution to eliminate potential
delay in the execution of a complete upgrade to the mechanical equipment. For
example,i the interim solution may reduce or eliminate the delay for an
upgrade,
where requisite components are not immediately available or qualified service
personnel are not available for a complex service procedure. The interim
solution
covers the time period after a noncompliance with the desired configuration is
detected and prior to placing the actual configuration in conformity with the
desired configuration. The interim solution may define time/operational
limitations or restrictions for the mechanical equipment prior bringing the
discrepant component of the mechanical equipment into conformity. The interim
solution may entail restricted usage of the non-conforming equipment. Further,
the human resources requirement may include provisional operational training
to
properly operate the mechanical equipment under the time/operational
limitations
or restrictions.
The component requirements (e.g., part requirements) are forwarded over
the output communications interface 32 to the materials management system 36
or
another computer system that supports purchasing or procurement of components
for the mechanical equipment. The materials management system 36 is a
computer system for obtaining components for the mechanical equipment from a
supplier or obtaining components from existing internal sources (e.g., a parts
depot
or a warehouse). The component requirements may include a quantity, a
description, a manufacturer's equivalent component (e.g., part) number, or
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component (e.g., part) parameters. With respect to mechanical equipment that
has
a software component, the component requirements may include version or
revision information or any other parameter necessary to provide the upgrade
of
the software configuration associated with the mechanical equipment.
In an alternative embodiment, the parts requirements are forwarded over to
an enterprise resource planning system, rather than the materials management
system 36. An enterprise resource planning system is a computer system that
facilitates the exchange of information between different operational or
business
systems of a business entity. For example, an enterprise resource planning
system
may facilitate the exchange of information between purchasing, engineering,
manufacturing, and management systems of a corporation.
In general, the supervisory database 28 supports management's oversight of
the managing of the configuration. Additionally, the supervisory database 28
retains the historical records of prior configuration alterations. The
supervisory
database 28 tracks historic configurations of the mechanical equipment and any
associated failure or defect with historic configurations. A description of
the
failure or defect, a date of detection of the failure of defect, determined
causal
factors from failure analysis activities, and resolution or repair of the
failure or
defect are preferably noted in the supervisory database 28. The foregoing
failure
or defect data may supplement or be used to update mean-time-before failure
(MTBF) data provided by the manufacturer on parts or assemblies of the
equipment. In turn, the updated MTBF may be used to change the desired
configuration with input from engineering over the engineering input/output
device 12.
The supervisory database 28 may record approvals of engineering changes
to the desired configuration database 24. In addition, the supervisory
database 28
may record and archive approvals of work, past configurations, or inspections
by
maintenance staff. Thus, the supervisory database 28 promotes accountability
of
mechanics, technicians, engineers, and management for activities related to
managing the configuration. This supervisory database 28 may represent a
repository of historical records, including satisfaction records of executed
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configuration changes for the purpose of regulatory compliance, safety
compliance, or otherwise.
FIG. 2 is a diagram that illustrates an example of a hierarchical data
structure 52 that may be used to practice the invention. The hierarchical data
structure 52 of FIG. 2 may be used to store data in the actual configuration
database 22, the desired configuration database 24, or both. For example, the
hierarchical data structure 52 of FIG. 2 may be used as a template for
conf guration data to be stored prior to populating the actual configuration
database ~22 and the desired configuration database 24 with the configuration
data.
A hierarchical data structure 52 defines one configuration of the
mechanical equipment that is valid for a validity duration. Accordingly, the
multiple hierarchical data structures 52 are associated with corresponding
configurations of mechanical equipment in the actual configuration database
22,
the desired configuration database 24, or both. A configuration of mechanical
equipment has equipment level data 46, assembly level data 48, and part level
data
50. The assembly level data 48 and part level data 50 may be referred to as
component level data. The equipment level data 46 occupies the highest level
of
the hierarchy, whereas the part level data 50 occupies the lowest level of the
hierarchy in the example illustrated in FIG. 2. In actual practice, the
assembly
level data 48 may occupy multiple tiers of the hierarchical data structure 52.
Accordingly, a component (e.g., a part or an assembly) may be introduced into
more than one single level of the hierarchy. The assembly level data 48
occupies
an intermediate level or intermediate levels of the hierarchy, as illustrated.
The
equipment level data 46 may contain references to the intermediate assembly
level
data 48, the part level data 50, or both. The equipment level data 46, the
assembly
level data 48, and the part level data 50 represent configuration data, which
may
vary with time, defined conditions, or both.
In an alternate embodiment, the hierarchical data structure may contain
additional levels to the hierarchy, such as a subassembly level intermediate
to the
assembly, level data 48 and the part level data 50.
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The equipment level data 46 includes an equipment identification (e.g.,
equipment identifier), equipment description data, equipment specification
data,
utilization history data, and a maintenance history data. Further, the
equipment
level data 46 may contain an equipment breakdown of the equipment in terms of
a
list of assembly identifiers, part identifiers, or both that constitute the
equipment.
The utilization history data may include parameters such as hours of active
operation of the mechanical equipment, distance traveled by mobile mechanical
equipment, years of continued service, or the like. The maintenance history
data
may contain a record of parts and assemblies replaced on a given mechanical
equipment and associated replacement dates. The maintenance history data may
include a log of routine service performance. The maintenance requirement plan
data may also be associated with equipment definition or integrated with the
equipment definition to form a cohesive, integrated upgrade plan.
The assembly level data 48 includes an assembly identification (e.g.,
assembly identifier), assembly description data, assembly specification data,
installed location data, usage data, installed position date data, utilization
history
data, maintenance history data, and assembly longevity data. The assembly
level
data 48 preferably includes a maintenance requirement plan for maintaining the
assembly in proper operational order. Further, the assembly level 48 may
contain
an assembly breakdown of the equipment in terms of part identifiers,
subassemblies, or other components that constitute the equipment.
The installed location data defines a mounting position of the assembly
with respect to the mechanical equipment. The installed position data defines
a
position of a component or part of the assembly with respect to the assembly.
The
assembly longevity data may represent a MTBF estimates for a corresponding
assembly. The longevity data may be expressed in terms of one or more of the
following parameters: (1) time and in service, (2) operational cycles, (3)
chronological age, (4) physical operational conditions, and (5) other
expressions of
longevity of service. The operational conditions include temperature,
pressure,
induced loads, and the like. The MTBF information may be provided by a
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manufacturer and validated or updated by subsequent testing and monitoring of
the performance of the assembly.
The part level data 50 includes a part identification (e.g., part identifier),
part description data, part specification data, installed location data,
installed
position data, installation date, utilization history, manufacturing serial
numbers
(e.g., lot numbers), date of manufacture, utilization data, maintenance
history data,
and part longevity data. A manufacturer or an affiliate of the manufacturer
assigns
manufacturing serial numbers and a date of manufacture the a part. Part
longevity
data may represent an MTBF estimate for a corresponding part. The MTBF may
be provided by a manufacturer and validated or updated by subsequent testing
and
monitoring of the performance of the part.
FIG. 3 is a flow chart of a method for managing a configuration of
mechanical equipment. The method of FIG. 2 begins in step S 10.
In step S 10, a desired configuration of the mechanical equipment is
established based on an engineering design or objective that meets a
reliability,
safety, or' performance goal of the mechanical equipment. For example, the
engineering design may be configured to meet a reliability goal based on
statistical
failure data on parts, assemblies, or the entire mechanical equipment.
Accordingly, the user of the engineering input/output device 12 may wish to
update the previously desired configuration with a current desired
configuration
because of an engineering change.
A user of the engineering input/output device 12 (e.g., a computer work
station) enters a desired configuration of the mechanical equipment into the
desired configuration database 24 based on compliance with one or more of the
following criteria: technical specifications, reliability, availability of
equipment,
safety regulations, regulatory requirements, and performance requirements. In
one
example, the user may enter an update of the desired configuration into the
engineering input/output device 12 to foster compliance with a new technical
standard. In another example, the desired configuration may be updated on
regular basis after an evaluation of reliability feedback on the mechanical
equipment, an assembly thereof, or a part thereof. In yet another example, a
user
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of the engineering input/output device 12 may establish the desired
configuration
based upon operational performance of a part, an assembly, a component, or an
entire mechanical equipment.
An update to the desired configuration may involve replacing an old part
having a lesser longevity with a substituted part having a greater longevity.
Likewise, an update to the desired configuration may involve replacing an old
assembly having a lesser longevity with a substituted assembly having a
greater
longevity.
In step S 12, an actual configuration of the mechanical equipment is
evaluated based on measurement analysis of system or component performance to
a specification, an inspection or reference to an up-to-date actual
configuration
database 22. An actual database may be referred to as an as-maintained
database
because the database generally indicates the as-maintained or current
condition of
the mechanical equipment. An actual configuration database 22 may be
considered up-to-date if an inspection was recently conducted within a maximum
time interval from the present time. The actual configuration may be
determined
or verified based on disassembly and inspection of at least a portion of the
mechanical equipment. A user of the maintenance input/output device 10 (e.g.,
computer work station) enters an actual configuration of the mechanical
equipment into the actual configuration database 22 based on a physical
inspection, a visual inspection, a test of the mechanical equipment, or
reference to
an up-to-date actual configuration database 22.
In step S 14, the data processor 30 determines if the actual configuration
complies with the desired configuration for the mechanical equipment. For
example, the data processor 30 determines compliance based upon the logical
and
physical configuration of the mechanical equipment expressed as configuration
data with respect a particular time. The data processor 30 retrieves records
of
configuration data from the actual configuration database 22 and the desired
configuration database 24 that are associated with the same mechanical
equipment. The configuration data is generally time sensitive. The actual
configuration and the desired configuration may be associated with time stamps
to
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facilitate an evaluation of the latest condition of the mechanical equipment.
The
time stamps may indicate absolute time or a relative time relationship between
the
actual configuration and the desired configuration data.
The data processor 30 may query or search the actual configuration
database 22 and the desired configuration database 24 by equipment identifier,
assembly identifier, or part identifier to retrieve records for the same
mechanical
equipment. The records may be organized as files or another suitable data
structure. Once one or more records for the mechanical equipment are
retrieved,
the data processor 30 may compare data records on a record-by-record basis,
where the compared records of configuration data are associated with
substantially
the same time period. The data processor 30 identifies and flags differences
in the
physical and logical configuration of the mechanical equipment between actual
configuration data and the desired configuration data associated with the same
time period.
In one embodiment, the retrieval records from the desired configuration
database 24 and the actual configuration database 22 may be limited to records
affected by recent changes or updates to the desired configuration database
24.
The limiting of the retrieval and comparison to affected records reduces the
load
on the processor 30 that would otherwise result from a comparison of all
records
related to, an equipment identifier. Accordingly, the processing time of the
data
processor 30 may be reduced commensurately with the reduction in the load.
In an alternative embodiment, the data processor 30 preferably considers all
or most of the records for an applicable time period and an applicable
equipment
identifier (or an entire configuration), in the desired configuration database
24 for
the comparison with the actual configuration database 22. The configuration
may
be expressed in terms of a physical configuration, a logical configuration, or
both.
The physical configuration, the logical configuration, or both may vary with
time.
The configuration may be defined by a temporal parameter to indicate the
status of
the configuration at a particular time, with a range of times, or the like. If
the data
processor 30 determines that the actual configuration does not comply with the
desired configuration, the method continues with step S 16. However, if the
data
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processor 30 determines that the actual configuration does comply with the
desired
configuration, the method ends with step S 18.
In step S 16, the data processor 30 plans upgrade requirements to upgrade
the actual configuration to the desired configuration if the actual
configuration is
noncompliant. The data processor 30 may determine the upgrade requirements by
comparing the actual configuration to the desired configuration with regards
to
physical, logical, and time characteristics associated with the actual
configuration
and the desired configuration. For example, the data processor 30 may identify
a
component (e.g., part or subassembly) of the mechanical equipment that is
noncompliant (physically, logically or temporally) with the desired
configuration.
The identified noncompliant component may be stored in the upgrade
requirements database 26 along with an associated equipment identifier for the
mechanical equipment. Further, the upgrade requirements may contain requisite
labor requirements, modification instructions, supporting tool and equipment
information, and acceptance criteria to install the identified noncompliant
component and achieve the desired (i.e., upgraded) configuration.
The upgrade requirements database 26 may send the identified part
number, a requirement date, and other informational elements required to
achieve
the upgraded configuration, or both to the materials management system 36. In
turn, the materials management system 36 facilitates the timely
acquisition/provisioning of a component (e.g., part, or subassembly) and other
measures that support the upgrade effort represented by the component in a
timely
manner. .In one embodiment, the materials management system 36 or purchasing
system may be manned by purchasers or administrators to procure required parts
and assemblies.
The upgrade requirements data preferably includes scheduling data and
planning data for bringing together resources, such as an end item's
availability,
the requisite parts, tools, equipment for support of the effort, modification
instructions for the human resources, acceptance criteria with testing
equipment
and repair personnel at a specific time and place to complete upgrade
requirements
to achieve the desired configuration.
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The planning of maintenance, repair and overhaul activities of step S 16
may be executed in accordance with several alternative techniques that are not
mutually exclusive. In accordance with a first technique, the planning of step
S 16
includes procuring a required part for the desired configuration and
scheduling
human resources consistent with availability of the required part. In
accordance
with a second technique, step S 16 includes procuring the required assembly
for the
configuration and scheduling human resources consistent with the availability
of
the required assembly. In accordance with a third technique, step S 16
includes
providing part level data on the mechanical equipment to a user via an
input/output device (e.g., maintenance input/output device 10) for a given
point in
time within a usable life of the mechanical equipment. In accordance with a
fourth technique, step S 16 includes providing a serial number of a component
of
the mechanical equipment at any given point in time for a given point in time
within its usable life to manage the at least one of the safety, reliability,
and
performance. In accordance with a fifth technique, step S 16 may include
scheduling and bringing together at least two of the following items at a
specific
time and ;place: requisite parts, technical instructions, supporting
equipment,
acceptance criteria and procedures, tools, and repair personnel.
In another embodiment of a data processing system shown in FIG. 4, the
materials management system 36 system may be automated to communicate to a
supplier's computer system 58 via a business-to-business server 54 and a
communications network 56. FIG. 4 is similar to FIG. 1 except the business-to-
business server 54 provides a communications interface between the materials
management system 36 of one business entity to the computer system 58 (e.g.,
customer fulfillment center) of another business entity. The business-to-
business
server 54; may facilitate the exchange of data over the communications network
56
(e.g., the.Internet) to support the automated transactions. Like reference
numbers
in FIG. 1; and FIG. 4 indicate like elements.
FIG. 5 shows a graph that illustrates how configuration data associated
with different equipment identifiers varies over time. An x axis represents
equipment identifiers. here, for purposes of illustration, the equipment
identifiers
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are represented by integer numbers ranging from 1 to n. A y axis represents a
set
of configuration data or a configuration. Each configuration may be expressed
as
a collection of different components along with relationships between or among
the components. The z axis represents time. As shown in FIG. 5, the x axis,
the y
axis and z axis are generally orthogonal to each other.
Although the configuration data may be maintained for virtually any
number of unique equipment identifiers, FIG. 5 shows respective groups (65,
75)
of configurations associated with two equipment identifiers (1,2). The first
group
65 of configurations includes a first configuration 60 at a reference time, a
second
configuration 62 at the reference time plus an interval, a third configuration
64 at
the reference time plus another interval, and a fourth configuration 66 at the
reference time plus another interval. The second group 75 of configurations
includes a first configuration 70 at a reference time, a second configuration
72 at
the reference time plus an interval, a third configuration 74 at the reference
time
plus another interval, and a fourth configuration 76 at the reference time
plus
another interval. The reference time for the first group 65 and the second
group 75
may be the same or different. The equipment identifier may be affiliated with
a
series of successive configurations from creation of the mechanical equipment
to
destruction or end of life of the mechanical equipment. The data processing
system 16 of the invention facilitates the tracking of the successive
configurations
associated with corresponding equipment identifiers. In accordance with FIG.
5,
the data processing system 16 may store the first configuration through the
third
configuration, while designating the fourth configuration the latest as-
maintained
or current configuration of the mechanical equipment.
Although the method of maintaining the configuration of the mechanical
equipment may be applied to numerous types of machinery, in one example, the
mechanical equipment represents an aircraft. In the case of the aircraft, the
equipment identifier may be referred to as a tail designator. The
configuration of
an airplane may be defined by a tail designator. Every tail designator (e.g.,
tail
number) has a unique configuration, scheduling, and planning requirements.
Even
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the same model of aircraft may differ because of variations in maintenance
activity
or part substitutions during manufacturing.
A.tail designator is a unique identifier. Each tail designator provides a
mechanism for tracking the profitability or maintenance expense of an
associated
aircraft. Further, each aircraft can be regarded as a profit/loss center that
is
identified by the tail number of the aircraft.
Even the same model or model numbers of planes may differ because of
maintenance activity or part substitutions during manufacturing. A tail number
may represent a group or list of constituent parts. That is, each tail
designator may
be associated with an entire configuration of an aircraft. The configuration
defines
the list of constituent part as well as one or more relationships between the
constituent parts or between constituent parts and the entire aircraft.
The upgrade requirements coordinate the delivery of one or more following
items to the location of the aircraft: labor, skills, parts, technical
instructions,
acceptance criteria, tools, support and testing equipment. The location of the
aircraft may vary over time in the context of a mobile airplane. For example,
the
aircraft may comprise a commercial plane that transports passengers between
two
or more cities. The system and method coordinates the availability of labor
and
parts to fix an airplane at a particular location at a specific time. This
upgrade
requirement will also define the disposition of removed or replaced prior
elements
of the equipment configuration. The upgrade requirements for the aircraft may
be
specific to certain parts of the aircraft. For example, the upgrade
requirements
may apply just to an engine of a plane, rather than the entire plane. The
maintenance plan may consider the longevity or life expectancy of constituent
components as well as the life expectancy of the entire aircraft. For example,
an
aircraft engine may have a life expectancy separate from the airplane itself.
The method of maintaining a desired configuration of mechanical
equipment facilitates compliance with regulations and laws by tracking an
actual
configuration of the mechanical equipment and providing a structured update
procedure. The desired configuration or its underlying specifications may be
established so that they meet applicable regulatory standards or are approved
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regulatory authorities. As regulations and laws change, the desired
configuration
database 24 readily supports updating in a timely manner to facilitate
compliance.
The method of maintaining a desired configuration may be used to maximize the
longevity of parts and assemblies to extend the longevity of the mechanical
equipment. Incremental increases in the longevity and commercial use of
capital-
intensive infrastructure may lead to decreased expenditures (or at least
delayed
expenditures) for new capital equipment. Maintaining a desired configuration
may lead to more predictable longevity for the mechanical equipment, standard
inventories of parts, which may permit reduced inventory of spares and
replacement parts. The reliability of the equipment may be enhanced by weeding
out poor performing parts, poor performing assemblies, or even poor performing
mechanical equipment.
The data processing system 16 is well-suited for responding in a timely
manner to the configuration-related events in the supply chain of components,
in
the inventory management of components and human resources for maintaining
the nyechanical equipment, and in the financial management of the mechanical
equipment.
Using the above system, one or more databases of configurations of
mechanical equipment are maintained. FIG. 6 shows the desired configuration
database 24 including a functional configuration database 600 and a logical
configuration database 610. FIG. 7 shows the actual configuration database 20
including a physical configuration database 700 and operational configuration
database 710. The functional configuration database 600 stores functional
information about an end item and internal components of the end item. The
logical configuration database 610 corresponds to the functional configuration
database ,600. The logical configuration database 610 is a generally more
detailed
definition of the functional configuration database 600 and typically
possesses a
more system connective view of the end items' functional configuration
database
600. The physical configuration database 700 stores physical information about
the end item. The operational configuration database 710 stores operational
information about the end item.
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The information that can accompany the functional configuration database
600, logical configuration database 610, physical configuration database 700
and
operational configuration database 710 can be described by way of the
following
example. Regarding the desired configuration database 24, with regard to an
aircraft, for example a Boeing 737, a functional configuration of the aircraft
is a
device that will move 150 passengers 600 miles at a speed less than the speed
of
sound, 35,000 feet, and uses two engines. The logical configuration of the
aircraft
with two,engines includes one engine under each wing, a 78 foot long fuselage,
and a wing span of 62 feet, the fuselage being manufactured of aluminum. Those
skilled in the art will appreciate that the logical configuration of the
aircraft can
include other information, such as, a take off weight of x thousands of
pounds,
carrying x amount of fuel in a certain type of tanks connected to certain
pumps to
move the fuel, and a the aircraft including a certain take off thrust. The
logical
configuration and functional configuration information typically addresses
broad
categories of the aircraft. The logical configuration information corresponds
to a
functional description within specific families of the aircraft. For example,
aircrafts including digital cockpits versus aircrafts with analog cockpits
addresses
two logical configurations used within the functional description of cockpits.
Regarding the actual configuration database 20, a physical configuration
includes a specific instance of the logical configuration. The physical
configuration information includes specific data about an end item, e.g., the
aircraft. For example, the physical configuration database could include
information regarding a serial number of the.end item. Those skilled in the
art will
appreciate that other information could be included such as a part number of
configurable components, processes, manufacturers, and a logical configuration
descriptor for the end item part number or configurable component and
providers.
Regarding the aircraft example, a specific instance of a logical configuration
might
include aircraft serial number 12345 containing two Pratt & Whitney engines,
one
with serial number PW 001 and the other with serial number PW 099. To
accommodate more than one aircraft, e.g., more than one end item, the physical
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configuration database can include separate databases for each of the end
items or
can include one database for all of the end items.
The logical configuration descriptor describes physical configuration
information in terms of a logical configuration. For example, a power plant
includes an engine, and in the context of an aircraft, an engine includes a
jet
engine. Depending on the type of aircraft and application for the aircraft,
the jet
engines include a certain variety and type. The logical configuration
descriptor is
helpful, for example, when an operator does not, or cannot, know the serial
number or part number of certain parts.
The operational configuration includes information about the aircraft
concerning the operation of the aircraft. For example, the fuselage is
pressurized
as the aircraft ascends to 35,000 feet. Changes occur to the aircraft and
systems,
subsystems, components and parts of the aircraft due to the pressure. In
addition,
changes occur to the aircraft due to other factors, such as the operational
environment, for example, the weather environment. These changes can be
measured and stored as operational information that can be used in predictive
maintenance. For example, an operator may need to understand how many cold
cycles the fuselage of the aircraft has been through and how many
overpressures
the fuselage has gone through. Operating profiles, for example, of the systems
and
components of the aircraft are monitored and operational information is
gathered
and stored in the operational configuration database 710. Thereafter,
interrelationships may be established between a plurality of profiles. For
example,
possible connectivity between profiles includes landings on short runways
immediately following periods of flight greater than 3 hours with wing spar
temperatures below- 50 degrees Celsius and landings on short runways with over
50% of outboard wing fuel tanks full.
Thereafter, a database of configurations of mechanical equipment is
maintained in accordance with the functional configuration database 600, the
logical configuration database 610, the physical configuration database 700
and
the operational configuration database 710. Moreover, additional databases may
be established, such as, configuration management, predictive maintenance,
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configuration modification planning and scheduling, component acquisition, and
maintenance execution. The functional configuration database 600, logical
configuration database 610, physical configuration database 700 and
operational
configuration database 710 can be utilized in conjunction with the databases
and
information processing rule sets and associated algorithms related to, and
supportive of or dependent on, one or more of configuration management,
predictive maintenance, configuration modification and scheduling, component
acquisition, resource allocation in an MRO environment, maintenance planning
and scheduling, and maintenance execution. Moreover, the logical configuration
database 610, physical configuration database 700 and the operational
configuration database 710 can be integrated to analyze and create the upgrade
requirements database 26 containing information about the end item and
components of the end item
The foregoing description of the method and system describes several
illustrative examples of the invention. Modifications, alternative
arrangements,
and variations of these illustrative examples are possible and may fall within
the
scope of the invention. Accordingly, the following claims should be accorded
the
reasonably broadest interpretation, which is consistent with the specification
disclosed herein and not unduly limited by aspects of the preferred
embodiments
disclosed herein.
24
