U.S. patent application number 10/806733 was filed with the patent office on 2004-09-16 for method and apparatus for managing maintenance operations.
Invention is credited to Budnik, Daniel J., Hawman, Michael W., Roberts, Michael A..
Application Number | 20040181330 10/806733 |
Document ID | / |
Family ID | 23147204 |
Filed Date | 2004-09-16 |
United States Patent
Application |
20040181330 |
Kind Code |
A1 |
Hawman, Michael W. ; et
al. |
September 16, 2004 |
Method and apparatus for managing maintenance operations
Abstract
A computerized method of assisting the routing of a part,
comprising the steps of: providing at least one computer; receiving
part identifier information; and generating a tag for affixing to
the part. The tag has information thereon responsive to the
identifier information. A computerized method of assisting the
handling of a part, comprising the steps of: providing at least one
computer; receiving part identifier information; processing the
part identifier information; and generating output from the
computer responsive to the part identifier information. A
computerized method of tailoring work instructions to perform on a
part, comprising the steps of: providing at least one computer
having memory with global work instructions relevant to a plurality
of parts and to a plurality of work locations; receiving part
identifier information and work location information; processing
the part identifier and work location information; and generating
tailored work instructions from said computer responsive to the
part identifier and work location information. A computerized
method of dispositioning of parts, comprising the steps of:
providing at least one computer; receiving part identifier
information for first and second part; determining a disposition of
the first part then the second part, each disposition responsive to
the part identifier information; determining whether the second
part disposition requires adjustment to the first part disposition;
and if necessary, modifying said first part disposition.
Inventors: |
Hawman, Michael W.; (Vernon,
CT) ; Budnik, Daniel J.; (Southington, CT) ;
Roberts, Michael A.; (Wethersfield, CT) |
Correspondence
Address: |
PRATT & WHITNEY
400 MAIN STREET
MAIL STOP: 132-13
EAST HARTFORD
CT
06108
US
|
Family ID: |
23147204 |
Appl. No.: |
10/806733 |
Filed: |
March 23, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10806733 |
Mar 23, 2004 |
|
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|
10064105 |
Jun 11, 2002 |
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60297653 |
Jun 12, 2001 |
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Current U.S.
Class: |
701/100 ;
700/215 |
Current CPC
Class: |
G07C 3/00 20130101; G06Q
10/06 20130101 |
Class at
Publication: |
701/100 ;
700/215 |
International
Class: |
G06F 019/00 |
Claims
1. A computerized method of assisting the routing of a part,
comprising the steps of: providing at least one computer; receiving
part identifier information; and generating a tag for affixing to
said part, said tag having information thereon responsive to said
part identifier information; wherein a user reviews said
information on said tag and routes said part accordingly.
2. The method of claim 1, further comprising the steps of:
evaluating a characteristic of said part based upon said
information on said tag to determine a disposition of said part;
receiving said disposition of said part; and generating a new tag
for affixing to said part, said tag having information thereon
responsive to said part characteristic; wherein said user can
review said information on said tag and route said part
accordingly.
3. The method of claim 1, wherein said part identifier information
includes a part number.
4. The method of claim 3, wherein said part identifier information
also includes a serial number.
5. The method of claim 1, further comprising the step of generating
an electronic record of said part.
6. A computerized method of assisting the handling of a part,
comprising the steps of: providing at least one computer; receiving
part identifier information; processing said part identifier
information; and generating output from said computer responsive to
said part identifier information; wherein a user reviews said
output and handles said part accordingly.
7. The method of claim 6, wherein said part identifier information
includes a part number.
8. The method of claim 7, wherein said part identifier information
also includes a serial number.
9. The method of claim 6, wherein said output comprises routing
instructions.
10. The method of claim 6, wherein said output comprises work
instructions.
11. The method of claim 6, further comprising the steps of:
receiving a disposition of said part in response to said output;
processing said part disposition; and generating output from said
computer responsive to said part disposition.
12. A computerized method of tailoring work instructions to perform
on a part, comprising the steps of: providing at least one computer
having memory with global work instructions therein, said global
work instructions relevant to a plurality of parts and to a
plurality of work locations; receiving part identifier information
and work location information; processing said part identifier
information and said work location information; and generating
tailored work instructions from said computer responsive to said
part identifier information and said work location information;
wherein a user reviews said tailored work instructions and performs
said tailored work instructions accordingly.
13. The method of claim 12, wherein said processing step comprises
searching said global work instructions for tasks relevant to said
part and said work location.
14. A computerized method of dispositioning of parts, comprising
the steps of: providing at least one computer; receiving part
identifier information for a first part; determining a disposition
of said first part responsive to said first part identifier
information; receiving part identifier information for a second
part to said computer; determining a disposition of said second
part responsive to said second part identifier; determining whether
said second part disposition requires adjustment to said first part
disposition; and if necessary, modifying said first part
disposition; wherein a user reviews said first and second part
dispositions and dispositions said first and second parts
accordingly.
Description
[0001] "As-Shipped BOM" refers to a list of parts in the engine
when the OEM or the maintenance facility releases the engine to the
customer. Since the engine may undergo testing after assembly or
repair, the As-Shipped BOM may not be the same as the As-Built BOM.
If testing proves successful, the OEM or the maintenance facility
releases the engine and the As-Shipped BOM will mirror the As-Built
BOM. If testing proves unsuccessful, the OEM or the maintenance
facility may replace parts on the engine and perform additional
testing. Should the OEM or the maintenance facility replace parts,
the As-Shipped BOM may not be the same as the As-Built BOM.
[0002] Expected BOM refers to a list of parts that a maintenance
facility should find during disassembly of an engine during a
maintenance operation.
[0003] "As-Received Configuration refers to a list of parts
actually removed from the engine by the maintenance facility during
disassembly. If the maintenance facility performed the previous
maintenance operation, then the As-Received Configuration and
Expected BOM will be the same.
[0004] Planned Configuration refers to a preliminary list of parts
selected by the maintenance facility for reassembly into the
engine. The maintenance facility determines the Planned
Configuration by using the Expected BOM and the work scope to be
performed on the engine.
[0005] Should Build Configuration refers to a list of parts
selected by the maintenance facility for reassembly into the
product. Typically, the maintenance facility determines the Should
Build Configuration after completing disassembly of the engine.
[0006] Engine Manual ("EM") refers to a publication that contains
OEM and aviation authority (e.g. Federal Aviation Administration,
Joint Aviation Authority, etc.) approved engine maintenance
procedures.
[0007] Illustrated Parts Catalog ("IPC") refers to a publication
that provides part numbers and illustrations for parts used to
manufacture an engine and for replacement parts.
[0008] Service Bulletin ("SB") refers to a publication containing
OEM and aviation authority approved technical data for
incorporating an engineering change into an existing engine. The
Service Bulletin includes work instructions necessary to
incorporate the engineering change into the engine.
[0009] "Add Parts List refers to the parts that the Service
Bulletin can add to the engine.
[0010] Cancel Parts List refers to the parts that the Service
Bulletin can remove from the engine.
[0011] "Sets Requirement" refers to a stipulation in a Service
Bulletin that all of the parts on the Add Parts List must be added
to the engine and that all of the parts on the Cancel Parts List
must be removed from the engine. In other words, a Sets Requirement
prohibits partial incorporation of a Service Bulletin. A Service
Bulletin can have other types of sets requirements. For example, a
Sets/Stage Requirement may arise when an SB deals with multiple
locations within the engine (e.g. fifth and sixth stage compressor
blade locations). The Sets/Stage Requirement allows partial
incorporation of the SB by replacing all of the subject parts at
one location within the engine (e.g. replace all of the compressor
blades from the fifth stage, without replacing the sixth stage).
The maintenance facility would fully incorporate the SB during a
subsequent maintenance visit by replacing the sixth stage blades.
An Optional Set Dependency indicates related parts within the Add
Parts List. An assembly (such as a ring segment), which is formed
by various subcomponents (such as vane assemblies and pins),
typifies related parts within an SB. When an Optional Set
Dependency exists, the program will display the options available
for all of the related parts as a group.
[0012] A maintenance facility can perform a variety of maintenance
operations on an engine. In increasing order of complexity, these
maintenance operations include maintenance, repair and overhaul.
During any maintenance operation, the maintenance facility must
keep records in order to comply with the requirements of the
relevant aviation authorities. Conventionally, the maintenance
facility performed such record keeping manually.
[0013] While a maintenance facility may have conventionally relied
on computers for assistance, each area of the maintenance facility
(e.g. inspection, assembly, etc.) typically used a dedicated system
customized to the unique needs of that area. In other words, these
systems were not designed to coordinate with the computer systems
in other areas of the maintenance facility. This prevented
different areas within the same maintenance facility from sharing
data. Likewise, the computer systems at the maintenance facility
and at outside vendors were not connected so the entities could not
share data.
[0014] The parts involved in such a maintenance operation may
travel through multiple areas within the maintenance facility and
through outside vendors. Each internal area or outside vendor
performs a necessary function with respect to the part during the
maintenance operation. Conventional techniques do not readily track
the existence of a part within the maintenance facility nor the
flow of such part through the maintenance facility or through
outside vendors. In other words, one area of the maintenance
facility may lack visibility of part and part flow through other
areas of the maintenance facility or through an outside vendor.
[0015] The present invention manages these maintenance operations
without the aforementioned drawbacks of conventional
techniques.
SUMMARY OF INVENTION
[0016] It is, therefore, an object of the present invention to
provide a new and improved method and apparatus for managing
maintenance operations on a product.
[0017] It is a further object of the present invention to provide a
maintenance method and apparatus that reduces the number of steps
performed in a maintenance operation.
[0018] It is a further object of the present invention to provide a
computerized method and system for managing the maintenance, repair
or overhaul of a gas turbine engine.
[0019] It is a further object of the present invention to provide a
computerized maintenance method and system that reduces the number
of manual steps performed in a maintenance operation.
[0020] It is a further object of the present invention to provide a
maintenance method and apparatus that reduces the number of systems
dedicated to a specific area within the maintenance facility.
[0021] It is a further object of the present invention to provide a
maintenance method and apparatus that increases the visibility of
parts and part flow between areas of the maintenance facility.
[0022] These and other objects of the present invention are
achieved in one aspect by a computerized method of assisting the
routing of a part. The method comprises the steps of: providing at
least one computer; receiving part identifier information; and
generating a tag for affixing to said part, said tag having
information thereon responsive to said part identifier information.
A user reviews said information on said tag and routes said part
accordingly.
[0023] These and other objects of the present invention are
achieved in another aspect by a computerized method of assisting
the handling of a part. The method comprises the steps of:
providing at least one computer; receiving part identifier
information; processing said part identifier information; and
generating output from said computer responsive to said part
identifier information. A user reviews said output and handles said
part accordingly.
[0024] These and other objects of the present invention are
achieved in another aspect by a computerized method of tailoring
work instructions to perform on a part. The method includes the
steps of: providing at least one computer having memory with global
work instructions therein, said global work instructions relevant
to a plurality of parts and to a plurality of work locations;
receiving part identifier information and work location
information; processing said part identifier information and said
work location information; and generating tailored work
instructions from said computer responsive to said part identifier
information and said work location information. A user reviews said
tailored work instructions and performs said tailored work
instructions accordingly.
[0025] These and other objects of the present invention are
achieved in another aspect by a computerized method of
dispositioning of parts. The method comprises the steps of:
providing at least one computer; receiving part identifier
information for a first part; determining a disposition of said
first part responsive to said first part identifier information;
receiving part identifier information for a second part to said
computer; determining a disposition of said second part responsive
to said second part identifier; determining whether said second
part disposition requires adjustment to said first part
disposition; and if necessary, modifying said first part
disposition. A user reviews said first and second part dispositions
and dispositions said first and second parts accordingly.
BRIEF DESCRIPTION OF DRAWINGS
[0026] Other uses and advantages of the present invention will
become apparent to those skilled in the art upon reference to the
specification and the drawings, in which:
[0027] FIG. 1 is a flowchart of the steps involved in an overhaul
of an engine;
[0028] FIG. 2 is part of an Engine Inspection Record used during an
overhaul;
[0029] FIG. 3 is a schematic of a computer system capable of using
the present invention;
[0030] FIG. 4 is a screen generated on the computer system of FIG.
3 by a teardown module of the present invention;
[0031] FIG. 5 is a tag created by the teardown module of the
present invention;
[0032] FIGS. 6a-d are screens generated on the computer system of
FIG. 3 by an inspection module of the present invention; and
[0033] FIGS. 7a-c are various tags created by the inspection module
of the present invention.
DETAILED DESCRIPTION
[0034] Although the present invention will now be described in the
context of an overhaul at a maintenance facility, the present
invention could be used during any other type of maintenance
operation. In fact, the present invention may have applicability in
fields that require part tracking.
[0035] FIG. 1 shows a flowchart of an overhaul process 10. As a
first step 12, the maintenance facility defines the work scope to
be performed on the engine. The work scope includes the necessary
work instructions to perform an overhaul, along with the completion
of any Service Bulletins requested by the engine owner. The engine
owner and the maintenance facility typically generate the work
scope.
[0036] At a second step 14, the maintenance facility receives the
engine. In a third step 16, the maintenance facility tears the
engine down to part level. At a fourth step 18, the maintenance
facility inspects the parts. The inspection step determines, for
example, whether each part can be returned to service (i.e. a
serviceable part), requires rework, or must be removed from
service.
[0037] A fifth step 20 sources the parts that will be used when
assembling the engine. Based upon the results of the inspection in
step 18, the maintenance facility preferably routes a part based
upon whether the part is identified as: (1) serviceable; (2)
requiring rework; or (3) remove from service. The fifth step 20
also obtains any additional parts required to assemble the engine
(e.g. prepare a purchase order request).
[0038] A sixth step 22 assembles the engine with the parts obtained
by the fifth step 20, then tests the engine to ensure satisfactory
operation. Finally, a seventh step 24 ships the overhauled engine
to the engine owner.
[0039] Conventionally, the technician at the maintenance facility
consulted hard copies of the EM, IPC or other publications to
perform the third step 16 and the fourth step 18. Once
disassembled, the technician routed the parts to an inspector
(perhaps with intermediate stops at other locations in the
maintenance facility to, for example, clean or test the part).
[0040] The inspector receives the parts and determines the
condition of the parts in the fourth step 18. During this process,
the inspector must maintain adequate records. One example of such a
record keeping system is the Engine Inspection Record (EIR) used by
Pratt & Whitney of East Hartford, Connecticut.
[0041] Generally speaking, the EIR includes an MPL (also called a
Grand BOM) and a list of SBs that relate to each part number.
Although the maintenance facility produces the EIR with a computer,
the inspector enters data by hand on a hard copy printout of the
EIR. FIG. 2 displays a portion of an EIR during the inspection
portion of the overhaul process.
[0042] The EIR 32 lists all possible part numbers for each part in
section 34. The inspector indicates on the EIR 32 which part was
removed from the engine by circling the appropriate part number in
section 34. If the part has a serial number, the inspector will
enter the serial number of the part in section 36.
[0043] The inspector now performs any measurements or tests on the
part to determine whether the part could be reinstalled on the
engine. If the part needs rework, the inspector will generate a
work order to perform the necessary work on the parts. The
inspector could either manually create a work order, or enter the
necessary information into a dedicated computer (not shown) to
produce a work order electronically.
[0044] The EIR 32 also includes a section 34 that lists SBs and the
relationship between the part numbers and the SB. Likewise, the EIR
32 includes another section 38 that provides a list of possible
part numbers that could be reinstalled in the engine after the
maintenance operation. The inspector indicates in section 38 which
part number should be reinstalled on the engine after the
maintenance operation.
[0045] To make such a determination, the inspector would need to
consult the work scope of the maintenance operation produced in
step 12. Specifically, the inspector would need to review the work
scope for any of the SBs listed in section 34.
[0046] The inspector must now prepare the paperwork to have the
necessary work instructions performed to convert the removed part
to the part being reinstalled on the engine. For example, the
inspector may need to generate paperwork to have SBs performed on
the part removed from the engine.
[0047] The inspector must also remain cognizant of SBs that have
Sets Requirements. To do so, the inspector would consult the SBs
before generating the paperwork. In essence, the inspector reviews
the SBs to determine whether an SB affects other parts in the
engine. If a conflict does exist, the inspector may need to adjust
the work order accordingly (or even not allow incorporation of the
SB). Typically, this process involves numerous iterations.
[0048] After preparing the work order (which may be manually
generated or with the assistance of a dedicated computer), the
inspector manually enters work order information on another section
42 of the EIR 32.
[0049] The present invention represents a significant change from
the aforementioned conventional inspection process. The present
invention provides a tool to accomplish several tasks during the
maintenance operation. Different than with conventional methods,
the tool uses a computer system to assist actively with these
tasks. FIGS. 3-7c will be used to describe features of the tool
relevant to the present invention.
[0050] FIG. 3 provides a schematic representation of such a
computer system. Generally speaking, the computer system could
include a general purpose computer 100. The computer 100 should
have a suitable processor (not shown) to execute the program code,
memory (not shown) to store data and the program code, one or more
mass storage devices (not shown), one or more input devices 102
(e.g. mouse, keyboard or barcode scanner) and one or more output
devices 104 (e.g. monitor or printer).
[0051] The computer 100 could connect to a network 106 using
conventional connection technology (e.g. LAN, WAN, dial-up or
wireless). Using the network 106, the computer 100 could access one
or more remote resources, such as one or more servers 108.
[0052] The computer 100 should be capable of running a program
locally. The program may be written in any suitable programming
language, such as dynamic HTML or JAVA script. Preferably, the
program provides one of the output devices 104 with a graphical
user interface (GUI) to help the technician perform the
aforementioned tasks.
[0053] The server 108 could include the same components as computer
100. However, the server 108 should have the capability to process
and to store larger amounts of data than the computer 100. The
server 108 preferably stores the databases needed by the program.
Such databases include an MPL/Grand BOM database 110, an IPC
database 112 and an SB database 114.
[0054] The server 108 also includes a database 116 containing a
list of the SBs that the maintenance facility will perform during
the maintenance operation ("modification scope database") and a
database (not shown) containing a historical list of SBs previously
performed on the engine during earlier maintenance visits
("historical SB database"). As discussed earlier, the maintenance
facility determines the modification scope of the maintenance
operation before the engine arrives at the maintenance facility.
Another module (not shown) of the program helps the maintenance
facility create the modification scope database 116.
[0055] The server 108 should also include an Expected BOM database
118. Again, the Expected BOM is a list of the parts that the
maintenance facility should find in the engine during disassembly.
If the maintenance facility performed the last maintenance on the
engine, then the program could populate the Expected BOM database
118 with information from the As-Shipped BOM during the last
maintenance visit.
[0056] The server 108 should also include a Planned Configuration
database 120. Another module (not shown) of the program creates the
Planned Configuration database 120 by passing the modification
scope database 116 through the Expected BOM database 118. In other
words, the Planned Configuration database 120 is a list of parts
that should be reassembled into the engine upon performing the
planned modifications.
[0057] The program has multiple modules to assist the technician at
various stages of the maintenance operation. Several of these
modules will be described in detail below.
[0058] Although the present invention is preferably suited for use
by an inspector during the fourth step 18, the maintenance facility
may allow a technician to use a teardown module 200 of the tool
during the third step 16 of the maintenance operation process.
Namely, the maintenance facility uses the teardown module 200 when
disassembling the engine to part level.
[0059] Generally speaking, the teardown module 200 helps the
technician populate an As-Received Configuration database 122. In
other words, the technician advises the program of the actual parts
removed from the engine during disassembly. This feature is
particularly beneficial when the actual part was unexpected (i.e.
not in the Expected BOM database 118). The present invention allows
the maintenance facility to determine the impact of the unexpected
part and to begin looking for a suitable replacement part.
[0060] FIG. 4 displays a screen 202 from the teardown module 200.
The screen 202 includes a customer information section 204. The
technician can manually enter the service order number (or any
other suitable identifier) or choose the relevant service order
number by opening the drop-down box. A service order database (not
shown) populates the drop-down box with options.
[0061] The screen 202 also includes a filter section 206. The
filter section 206 allows the technician to limit information
provided in the screen 202. The filter section 206 could use any
suitable filtering method. For example, the filter section 206
allows the technician to display information by operational section
or another suitable format such as Air Transport Association
Specification 100 format. The technician can manually enter the
desired section by opening a drop-down box. The program can use the
IPC database 112 to populate the drop down box.
[0062] Based upon the information provided in the customer section
204 and the filter section 206, the program queries the IPC
database 112 to populate an illustration section 208 and a part
information section 210. This allows the technician to visually
compare the part removed from the engine with the IPC.
[0063] The part information section 210 could include information
from various databases. In particular, the part information section
210 may include information from the MPL/Grand BOM database 110,
the IPC database 112, the Expected BOM database 118 and the Planned
Configuration database 120. Using a hierarchy format (e.g. indents)
similar to that used in the operational section of the IPC, the
part information section 210 displays relevant information from the
MPL/Grand BOM database 110 (i.e. the selection appearing in filter
section 206). In other words, the part information section 210
lists, for the selection displayed in filter section 206, all
possible part numbers for the parts removed from the engine.
[0064] The part information section 210 could also indicate which
part numbers also reside in the Expected BOM database 118 and the
Planned Configuration database 120. FIG. 4 shows the use of printed
indicia ("(Planned)" and "(Expected)") to inform the technician.
However, the program need not notify the technician with the
planned or expected part information since the technician merely
removes the parts from the engine and is not involved in
configuration management.
[0065] The technician selects a selection box 212 adjacent to the
actual part removed from the engine with a mouse 102. If the part
is a serialized part, then the program will display a query window
(not shown) asking the technician to input the serial number of the
part. The program could also display a query window (not shown)
asking for time and cycle information for the part. With the
increased use of 2D bar-coding of engine parts, the technician
could merely scan the part with a hand-held scanner 102. Note that
2D bar-coding can contain both part number information and serial
number information.
[0066] After the technician selects the appropriate box 212, the
program performs several operations. First, the program creates an
electronic record (not shown) of the part. The electronic record
preferably assigns a unique identifier to the part for tracking
purposes. The electronic record could also include other relevant
information. For example, the electronic record could include
physical location information, routing information, work
instructions, and status information. The program adds or modifies
the electronic record as needed during the remainder of the
maintenance operation. The electronic records for each part removed
from the engine resides in a parts records database 124.
[0067] One benefit of the electronic part record is the ability for
other areas of the maintenance facility to view the record or to
use data from the record. Conventionally, such information was not
available to other areas of the maintenance facility. The only way
for an individual in the maintenance facility to obtain such
information using conventional techniques was to locate the part
within the maintenance facility and to read the associated
paperwork.
[0068] Second, the program adds the part number to an As-Received
Configuration database 122 on the server 108. This allows the
program to determine whether any parts removed from the engine were
"unexpected." That is, the part removed from the engine is not
found in the Expected BOM.
[0069] Upon recognizing an unexpected part, the program must
determine whether the modification scope of the maintenance
operation must change. If a change to the modification scope is
necessary, then the program notifies another area of the
maintenance facility of the unexpected part with an alert (not
shown). The alert also offers suggested changes to the modification
scope that would allow the maintenance facility to reuse the
unexpected part. The program performs this task in another module
(not shown) of the program by searching the SB database 114 to
establish whether the maintenance facility can perform one or more
SBs on the unexpected part to produce the planned part. Likewise,
the alert should notify the user if no suitable change exists (i.e.
the unexpected part cannot be reused in the engine).
[0070] Based upon this information, the other area of the
maintenance facility can modify the modification scope database 116
in another module (not shown) of the program in order to
disposition the unexpected part properly. When changing the
modification scope database 116, the program will also update the
Planned Configuration database 120.
[0071] Third, the program determines the immediate disposition of
the part. Specifically, the program determines whether or not the
maintenance facility can reuse the part when reassembling the
engine. The program can make this determination by querying the
Planned Configuration database 120 and, if necessary, the SB
database 114.
[0072] For example, the program could make this determination in
multiple steps. In a first step, the program could initially
determine if the part removed from the engine is in the Planned
Configuration. If so, then the maintenance facility may reuse the
part (assuming that later steps in the maintenance operation do not
reveal damage, etc. that makes the part unusable). In a second step
(for parts not in the Planned Configuration), the program will
query the modification scope database 120 to determine if one or
more SBs will reoperate the part removed from the engine to the
Planned Configuration. The remaining parts will not be reused when
assembling the engine. The program adds this disposition to the
electronic part record in any suitable manner.
[0073] Fourth, the program generates a tag 300 for affixing to
part. The program automatically generates the tag 300 with the
printer 104. The technician attaches the tag 300 to the part in any
known manner. Preferably, the tag 300 is the only paper generated
by the program. The program preferably keeps only electronic
records. If the part uses the aforementioned 2D bar-coding, then
the program need not create the tag and the part would travel
without any tag. The technician could merely scan the part to
determine any needed information by the program accessing the
electronic part record.
[0074] The tag 300 includes information found in the electronic
part record. Specifically, the tag 300 includes a part information
section 302, a customer information section 304, a status section
306, a bar code section 308 and a routing information section 310.
The tag 300 could, however, have more or less information thereon
as needed by the various locations within the maintenance
facility.
[0075] The program creates information for the status section 306
based upon the disposition of the part determined by the program
above. The status section 306 could display any suitable message.
Suitable messages include "Remove from Service" (e.g. to indicate
that the maintenance facility will not reuse the part) or "Created"
(e.g. to indicate that the maintenance facility may reuse the part,
assuming subsequent procedures or testing of the part confirm this
decision).
[0076] The bar code section 308 preferably corresponds to the
unique identifier assigned by the program in the electronic part
record. Other identification schemes could be used.
[0077] The routing information section 310 describes the flow of
the part through the maintenance facility in order to disposition
the part properly. For example, the routing information section 310
lists the specific areas within the maintenance facility that
should receive the part. The program determines the data for the
routing information section 310 based upon the status section 306
and other databases such as the EM or the Standard Practices Manual
(SPM).
[0078] To establish the proper part routing, the program must first
determine what operations and/or testing the part must undergo. In
other words, the program must assemble a work instruction database
126. The program assembles the work instruction database 126 from
relevant databases (e.g. the EM or the SPM). Since these relevant
databases assign unique numbers to the various tasks described
therein (e.g. task 72-33-01-990-001), the work instruction database
126 could merely be a listing of task numbers.
[0079] Based upon the locations within the maintenance facility
that will perform the work instructions, the program determines the
proper part routing to perform these tasks. FIG. 5 displays a
typical routing information section 310. Upon querying the
aforementioned databases, the program determined that the part must
undergo various procedures. Specifically, the figure displays that
the part must undergo a cleaning step and a non-destructive testing
step before the part travels to an inspector for a final
determination of disposition. The technician will route that part
(with the tag 300 attached) based upon the information provided on
the tag 300.
[0080] When the part arrives at the proper location within the
maintenance facility, a technician will scan the part with the
bar-code reader 102. The reader 102 scans the bar code section 308
of the tag. The program then accesses the electronic part record
within the parts records database 124 since the bar code
corresponds to the unique identifier assigned to the electronic
part record.
[0081] The program will then generate a screen (not shown) that
displays information relating to the relevant tasks from the work
instructions database 126. Notably, the program will only display
tasks specific to the area of the maintenance facility that
possesses the part. For example, when a technician from a cleaning
area of the maintenance facility scans the tag 300, the program
filters the work instruction database 126 to display only tasks
relevant to cleaning the part.
[0082] The screen should provide the technician with the actual
work instructions. The program provides such information by
displaying the relevant sections of the EM, SPM and/or the IPC.
[0083] The present invention has clear benefits over conventional
techniques. The first benefit is the reduction in paper.
Conventionally, the maintenance facility shipped additional
paperwork (e.g. work instructions) with the part. The present
invention (aside from the tag 300) is paperless. The process can be
paperless because the program will obtain the necessary information
from one or more of the databases on the server 108 and will
display such information as needed.
[0084] The second benefit is the reduction in unnecessary work
performed on the parts. Conventionally, the maintenance facility
never changed the preliminary disposition of the part. The
preliminary disposition never changed despite discoveries during
the subsequent removal of other parts that would have affected the
earlier disposition determination.
[0085] Take for example a subsequently removed unexpected part. The
maintenance facility may determine that a change to the
modification scope of the overhaul is necessary to include an SB
that reuses the unexpected part. The SB may also affect an earlier
removed part. The SB could, for example, replace the earlier
removed part with another part. Since the maintenance facility will
not reuse the part in the engine, the maintenance facility may not
need to perform as many, if any, tasks on the part. Conventionally,
the part would undergo these unnecessary tasks. Only when the part
arrived at the inspector section of the maintenance facility would
a realization occur that the original disposition is no longer
proper.
[0086] The present invention prevents the performance of such
unnecessary tasks. When altering the modification scope database
116, the program could flag the previously dispositioned parts
affected by the change to the modification scope database 116. When
the technician scans the part to perform an internal repair (or an
external repair should the vendor have access to the computer
system 100), the program would recognize the flag, alert the user
and print out a new tag 300 to reflect the newly revised
disposition of the part.
[0087] The technician notifies the program upon completion of the
work instructions. The program then modifies the work instructions
database 126 to indicate completion of the specific tasks. The
technician then routes the part to the next location designated in
the routing information section 310 of the tag. The program could
generate an updated tag 300 for the technician to affix to the part
as a replacement to the earlier tag 300.
[0088] Eventually, the tag 300 routes the part to an inspection
area of the maintenance facility. The inspection area makes the
final determination of part disposition. Although capable of use by
a technician during teardown, the preferred user of the present
invention is an inspector. The inspector examines the parts
previously removed from the engine by the technician.
[0089] FIGS. 6a-d display various shots of one embodiment of a
screen 402 from the inspection module 400. The screen 402 includes
a customer information section 404, a part information section 406
and various tabs 408, 410, 412, 414. The inspector could populate
the customer and part information sections 404,406 manually. If the
maintenance facility uses the teardown module 200, the program can
automatically populate the customer information section 404 and
part information section 406 when the inspector scans the tag 300
created by the technician.
[0090] In other words, the technician advises the program of the
actual parts removed from the engine during disassembly. The
inspector inputs the information in the same manner as described
above with respect to the technician using the teardown module 200.
If the part is serialized, the program could generate a window (not
shown) requesting additional information from the inspector. For
example with life limited parts, the program could seek information
regarding the number of hours and cycles since the last
measurement. The system 100 preferably keeps the old measurements
in a database on the server 108. The program will update the
database with the new information.
[0091] The various tabs 408-414 display the options that the
program makes available to the inspector. In the technical
information tab 408, the inspector can access particular
information from relevant publications by choosing the desired
publication and selecting the view button. The program then
searches the chosen database for relevant information, displaying
the relevant area of the publication in another window (not shown).
For example, should the inspector choose to view the EM, the
program would display portions of the EM specific to the part input
into the part information section 406 and relevant to an inspector
(such as visual inspection requirements for the part).
[0092] Once obtaining the necessary information from the technical
information tab 408 and performing the necessary tasks described
therein, the inspector can proceed to the configuration tab 410.
The configuration tab 410 allows the inspector to populate the
Should Build Configuration database 128 (if the maintenance
facility does not utilize the teardown module 200). The As-Received
part information previously supplied to the part information
section 406 helps the inspector determine the Should Build
Configuration.
[0093] Since a part may be used in more than one location within
the engine, the program assigns a location identifier (LID) to each
location in the engine. The LID could use any format. Preferably,
the LID has five fields. The first three fields of the LID
preferably correspond to ATA Chapter (e.g. 72), Section (e.g. 52)
and Subject (e.g. 00). The fourth field preferably corresponds to
the IPC Figure that displays the part. The fifth field preferably
corresponds to the Item Number in the IPC Figure assigned to the
part. The specific LID appears in a LID section 416. If a part
number appears within multiple LIDs, the program allows the
inspector to the select the specific LID after populating the part
information section 406.
[0094] After obtaining the received part number and LID, the
program then informs the inspector of the modifications relevant to
the part. The configuration tab 410 displays this information in a
modification information section 418. The modification information
section 418 displays the SBs relevant to the part listed in the
part information section 406. The program obtains this information
by searching the modification scope database 116 and the historical
SB database for instances of SBs that affect the part at that LID.
As seen in FIG. 6b, two SBs from these databases have effectivity
to the part at the LID.
[0095] The program will then inform the inspector of the parts
eligible to replace the part removed from the engine. The
configuration tab 410 displays this information in an eligible
replacement part section 420. The program obtains this information
using a two step process. First, the program determines all
potential replacement parts for the removed part at the LID by
iterating through the SBs listed in the modification information
section 414.
[0096] Second, the program removes from such list any potential
replacement parts that are excluded due to an earlier decision of
the inspector. For example, if a part chosen by the inspector for
reinstallation on the engine requires the incorporation of an SB
with a Sets Requirement affecting the current part, the program
will remove from consideration any potential parts that violate the
Sets Requirement. The program displays all valid potential
replacement parts in the eligible replacement part section 420.
[0097] The eligible replacement part section 420 also describes the
relationship between the removed part and each eligible replacement
part through the incorporation of the SBs. The program obtains this
information by querying the MPL database 110. For example, the
eligible replacement part section 420 displays that the two SBs
replace (rather than reoperate) the removed part with the planned
part. The inspector selects the desired eligible replacement in the
replacement part section 420 by double clicking the part number
with the mouse 102. The program then proceeds to the disposition
tab 412.
[0098] The disposition tab 412 allows the inspector to generate the
electronic paperwork necessary to perform necessary work (i.e. SBs)
on the part. As stated above, preferably the present invention does
not generate hard copy paperwork (aside from the tag 300).
[0099] The disposition tab 412 displays the options available to
the inspector. The program can tailor the options to the specific
maintenance facility. In FIG. 6c, the program allows the inspector
to: (i) identify parts as serviceable; (ii) remove parts from
service; (iii) allow part repair by an internal source; (iv) allow
part repair by an external vendor. The program will perform certain
tasks in response to the choice selected by the inspector.
[0100] The first choice available to the inspector in the
disposition tab 412 is to identify the parts as serviceable. The
maintenance facility can reinstall a serviceable part on the engine
in its current condition. In other words, the part meets the
inspection requirements in the relevant technical publications and
the modification workscope does not affect the part. The
serviceable part can travel directly to the kitting area of the
maintenance facility to await reassembly into the engine.
[0101] The program facilitates the routing of the part by
generating a new tag 300 (or, if the maintenance facility uses the
teardown module 200, by generating a replacement tag 300 for the
previously created tag 300). FIG. 7A displays the tag 300. The tag
300 could include similar information described above with the tag
300 created by the teardown module 200. Specifically, the tag could
include a routing information section 310 to reflect the
disposition selected by the inspector. In addition to the status
section 306, the tag 300 could include other indicia to display
part status. For example, the tag 300 could have a distinctive
color such as green. The program also updates the electronic part
record accordingly.
[0102] The second choice available to the inspector in the
disposition tab 412 is to remove the part from service. This means
the maintenance facility will not reinstall the part on the engine.
Similar to a serviceable part, the program facilitates this routing
by generating a new tag 300 (or, if the maintenance facility uses
the teardown module 200, by generating a replacement tag 300). FIG.
7B displays the tag 300. Specifically, the tag 300 could include a
routing information section 310 to reflect the disposition selected
by the inspector. In addition to the status section 306, the tag
300 could include other indicia to display part status. For
example, the tag 300 could have a distinctive color such as brown.
The program also updates the electronic part record
accordingly.
[0103] The part preferably should then travel to a review section
at the maintenance facility to determine if the part could be
reused in another engine or the maintenance facility must scrap the
part (i.e. no engine can use the engine). If the part will be
scrapped, the program can generate a new tag (not shown) with a
distinctive color such as red.
[0104] Since the maintenance facility will not reuse the part, the
maintenance facility must obtain a part for installation on the
engine. To assist this process, the program will alert the proper
location within the maintenance facility (e.g. purchasing) of the
need for a part. The location will obtain the needed part using
conventional techniques.
[0105] The third and fourth choices available to the inspector in
the disposition tab 412 are to allow internal and external part
repairs, respectively. This means that the part must undergo
repairs before the maintenance facility can reinstall the part on
the engine. A repair includes work instructions to fix wear or
damage to the part, or to incorporate one or more SBs.
[0106] To perform these repairs, the part can either remain within
the maintenance facility or travel to an external vendor. Similar
to serviceable parts and parts removed from service, the program
facilitates this routing of the part by generating a new tag 300
(or, if the maintenance facility uses the teardown module 200, by
generating a replacement tag 300). FIG. 7C displays the tag 300.
Specifically, the tag 300 could include a routing information
section 310 to reflect the disposition selected by the inspector.
In addition to the status section 306, the tag 300 could include
other indicia to display part status. For example, the tag 300
could have a distinctive color such as yellow. The program also
updates the electronic part record accordingly.
[0107] The program should also assemble the work instructions
necessary to complete the repair. Preferably, the program places
these instructions in the work instructions database 126 on the
server 108. This allows the program to display the work
instructions to the repair technician upon scanning the tag 300. As
described above, the program performs this feature by searching the
work instructions database 126 for tasks relevant to the subject
part.
[0108] If the repair source does not have access to the program,
the program should have the ability to print a hard copy of the
work instructions for sending along with the part.
[0109] When the repair source notifies the program of repair
completion, the program updates the work instructions database 126
and generates a new tag (not shown) to return the part to the
appropriate location (e.g. kitting or an inspector for external
repairs) within the maintenance facility.
[0110] The fifth option available to the inspector is to hold the
part temporarily. This option suspends further disposition of the
specific part. The inspector may now disposition other parts. The
inspector can return at a later time to disposition the part by
scanning the tag 300.
[0111] While dispositioning the parts in the inspection module 400,
the inspector can visit the status tab 414. The status tab 414
displays information relevant to the parts appearing in the Should
Build Configuration database 128. Next to the part information, the
status tab 414 includes a status indicator 422. The status
indicator 422 could have any suitable arrangement, including the
"stop light" arrangement shown in FIG. 6d.
[0112] The status indicator 422 adjacent the part number will stay
red until the inspector dispositions the entire quantity of the
given part number. Once disposition of the entire quantity has
occurred, the status indicator 422 adjacent to the part number
should turn yellow. After the repairs to the entire quantity of the
given part number have occurred and the entire quantity of parts
are available for reassembly into the engine (e.g. the parts arrive
in kitting), the status indicator 422 should turn green.
[0113] Once the inspector has populated the As-Received
Configuration database 122 and has dispositioned every part removed
from the engine, the program performs several final tasks. First,
the program will verify the validity of the parts chosen by the
inspector for reinstallation into the engine. The program
determines the validity by progressing the As-Received
Configuration database 122 through the modification scope database
116. The program then confirms that the selections made by the
inspector during the disposition process appear in the universe of
valid configurations. The program notifies the inspector with a
warning screen (not shown) if any discrepancies exist.
[0114] Note that the program could perform this first task again at
a later stage of the maintenance operation. For example, the
program could perform the validation when all parts arrive at
kitting.
[0115] Second, the program will then generate a Should Build
database 128. The presence of the Should Build database 128 is
beneficial to other areas of the maintenance facility. For example,
other areas of the maintenance facility can review the Should Build
database 128 for any logistical problems (e.g. part unavailability
or high part price). Another module (not shown) of the program can
assist the maintenance facility make any adjustments to the
modification scope to avoid such logistical problems.
[0116] The present invention has been described in connection with
the preferred embodiments of the various figures. It is to be
understood that other similar embodiments may be used or
modifications and additions may be made to the described embodiment
for performing the same function of the present invention without
deviating therefrom. Therefore, the present invention should not be
limited to any single embodiment, but rather construed in breadth
and scope in accordance with the recitation of the appended
claims.
* * * * *