Intelligent computer integrated maintenance system and method

A computer integrated manufacturing and maintenance system for controlling manufacturing and maintenance of a plurality of production complexes each of which includes a plurality of production machines, said computer integrated manufacturing and maintenance system comprising:

• an electronically stored master schedule file having therein a schedule of actual production and planned production for the plurality of complexes;
• means for controlling the plurality of production machines based upon the schedule of planned production in the master schedule file;
• an electronically stored parts manual, containing a hierarchical listing of parts in the plurality of production machines in the plurality of production complexes;
• first means, communicatively connected to said master schedule file, for obtaining a schedule of actual production and planned production for the plurality of complexes from the master schedule file;
• second means, communicatively connected to said first means and said electronically stored parts manual, for identifying parts in the hierarchical listing to be maintained during a predetermined time period, and a corresponding maintenance time during the predetermined time period for each identified part, based upon the obtained schedule;
• third means, communicatively connected to said second means, for reassigning the corresponding maintenance times for the identified parts, based upon the hierarchical listing of parts in the electronically stored parts manual, to reduce lost production time for each of the plurality of complexes;
• fourth means, communicatively connected to said third means, for generating a revised schedule of planned production based upon the reassigned maintenance times for the identified parts;
• and
• fifth means, communicatively connected to said fourth means and said master schedule file, for communicating the revised schedule of planned production to the master schedule file;
• whereby the plurality of complexes are controlled based upon the revised schedule of planned production to allow for maintenance activities while maximizing production.

A computer integrated maintenance method for use with a computer integrated manufacturing system, the computer integrated manufacturing system including a computer controller for controlling a plurality of production complexes each of which includes a plurality of production machines, the manufacturing system computer controller including an electronically stored master schedule file having therein a schedule of actual production and planned production for the plurality of complexes, the manufacturing system computer controller controlling the plurality of production machines based upon the planned production in the master schedule file;

• said computer integrated maintenance method being practiced on a maintenance operations computer controller and comprising the steps of:
• generating an electronically stored parts manual, containing a hierarchical listing of parts in the plurality of production machines in the plurality of production complexes;
• obtaining a schedule of actual production and planned production for the plurality of complexes from the master schedule file;
• identifying parts in the hierarchical listing to be maintained during a predetermined time period, and a corresponding maintenance time during the predetermined time period for each identified part, based upon the obtained schedule;
• reassigning the corresponding maintenance times for the identified parts, based upon the hierarchical listing of parts in the electronically stored parts manual, to reduce lost production time for each of the plurality of complexes;
• generating a revised schedule of planned production based upon the reassigned maintenance times for the identified parts;
• and
• communicating the revised schedule of planned production to the master schedule file;
• whereby the plurality of complexes are controlled based upon the revised schedule of planned production to allow for maintenance activities while maximizing production.

A compute integrated manufacturing and maintenance method for controlling manufacturing and maintenance of a plurality of production complexes each of which includes a plurality of production machines, the computer integrated manufacturing and maintenance method comprising the steps of:

• generating an electronically stored master schedule file having therein a schedule of actual production and planned production for the plurality of complexes;
• controlling the plurality of production machines based upon the planned production in the master schedule file;
• generating an electronically stored parts manual, containing a hierarchical listing of parts in the plurality of production machines in the plurality of production complexes;
• obtaining a schedule of actual production and planned production for the plurality of complexes from the master schedule file;
• identifying parts in the hierarchical listing to be maintained during a predetermined time period, and a corresponding maintenance time during the predetermined time period for each identified part, based upon the obtained schedule;
• reassigning the corresponding maintenance times for the identified parts, based upon the hierarchical listing of parts in the electronically stored parts manual, to reduce lost production time for each of the plurality of complexes;
• generating a revised schedule of planned production based upon the reassigned maintenance times for the identified parts;
• and
• communicating the revised schedule of planned production to the master schedule file;
• whereby the plurality of complexes are controlled based upon the revised schedule of planned production to allow for maintenance activities while maximizing production.

A computer integrated maintenance system for use with a computer integrated manufacturing system, the computer integrated manufacturing system including a computer controller for controlling a plurality of production complexes each of which includes a plurality of production machines, the manufacturing system computer controller including an electronically stored master schedule file having therein a schedule of actual production and planned production for the plurality of complexes, the manufacturing system computer controller controlling the plurality of production machines based upon the planned production in the master schedule file, said computer integrated maintenance system comprising:

• an electronically stored parts manual, containing a hierarchical listing of parts in the plurality of production machines in the plurality of production complexes;
• maintenance operations computer controlling means, adapted to be communicatively connected to the manufacturing system computer controller, and communicatively connected to the electronically stored parts manual, said maintenance operations computer controlling means comprising:
• maintenance schedule management means, for identifying parts in the hierarchical listing to be maintained during a predetermined time period based upon the planned production in the master schedule file, and for scheduling maintenance activities for the identified parts to reduce disruption of production;
• engineering change control management means, for integrating engineering change control activities into the scheduled maintenance activities;
• parts manual management means, for updating the hierarchical listing in response to maintenance activities and engineering change control activities;
• and,
• spares inventory management means, for generating requirements to order replacement parts for the identified parts to be available for use in the scheduled maintenance activities.

A computer integrated manufacturing and maintenance system for controlling manufacturing and maintenance of a plurality of production complexes each of which includes a plurality of production machines, said computer integrated manufacturing and maintenance system comprising:

• an electronically stored master schedule file having therein a schedule of actual production and planned production for the plurality of complexes;
• means for controlling the plurality of production machines based upon the planned production in the master schedule file;
• an electronically stored parts manual, containing a hierarchical listing of parts in the plurality of production machines in the plurality of production complexes;
• maintenance schedule management means, for identifying parts in the hierarchical listing to be maintained during a predetermined time period based upon the planned production in the master schedule file, and for scheduling maintenance activities for the identified parts to reduce disruption of production;
• engineering change control management means, for integrating engineering change control activities into the scheduled maintenance activities;
• parts manual management means, for updating the hierarchical listing in response to maintenance activities and engineering change control activities;
• and,
• spares inventory management means, for generating requirements to order replacement parts for the identified parts to be available for use in the scheduled maintenance activities.

A computer integrated maintenance system for a complex including a plurality of machines used to perform a primary function and which also require maintenance;

• said computer integrated maintenance system comprising:
• an electronically stored parts manual, containing a hierarchical listing of parts in the plurality of machines in the complex;
• and,
• maintenance operations computer controlling means, communicatively connected to said electronically stored parts manual comprising:
• first means for obtaining a schedule of actual and planned use for the plurality of machines;
• second means for identifying parts in the hierarchical listing to be maintained during a predetermined time period, and a corresponding maintenance time during the predetermined time period for each identified part, based upon the obtained schedule;
• third means for reassigning the corresponding maintenance times for the identified parts, based upon the hierarchical listing of parts in the electronically stored parts manual, to reduce lost use time for the complex;
• and
• fourth means for generating a revised schedule of planned use based upon the reassigned maintenance times for the identified parts;
• whereby use of the complex may be controlled based upon the revised schedule of planned use to allow for maintenance activities.

A computer integrated maintenance method for a complex including a plurality of machines used to perform a primary function and which also require maintenance;

• said computer integrated maintenance method being practiced on a maintenance operations computer controller and comprising the steps of:
• generating an electronically stored parts manual, containing a hierarchical listing of parts in the plurality of machines in the complex;
• obtaining a schedule of actual and planned use for the plurality of machines;
• identifying parts in the hierarchical listing to be maintained during a predetermined time period, and a corresponding maintenance time during the predetermined time period for each identified part, based upon the obtained schedule;
• reassigning the corresponding maintenance times for the identified parts, based upon the hierarchical listing of parts in the electronically stored parts manual, to reduce lost use time for complex;
• and
• generating a revised schedule of planned use based upon the reassigned maintenance times for the identified parts;
• whereby use of the complex may be controlled based upon the revised schedule of planned use to allow for maintenance activities.

A compute integrated maintenance system for a complex including a plurality of machines used to perform a primary function and which also require maintenance;

• said computer integrated maintenance system comprising;
• an electronically stored parts manual, containing a hierarchical listing of parts in the plurality of machines in the complex;
• maintenance operations computer controlling means, communicatively connected to the electronically stored parts manual, said maintenance operations computer controlling means comprising:
• maintenance schedule management means, for identifying parts in the hierarchical listing to be maintained during a predetermined time period based upon a planned use schedule for the machines, and for scheduling maintenance activities for the identified parts to reduce loss of use of the complex;
• engineering change control management means, for integrating engineering change control activities into the scheduled maintenance activities;
• parts manual management means, for updating the hierarchical listing in response to maintenance activities and engineering change control activities;
• and,
• spares inventory management means, for generating requirements to order replacement parts for the identified parts to be available for use in the scheduled maintenance activities.