Apparatus and method for tracking and managing physical assets

A computer based system automatically gathers, analyzes, and delivers information relating to the procurement and utilization of a plurality of such assets, such as a fleet of industrial equipment, so as to maximize productivity and to reduce operating costs and administrative burdens. Each of the assets is preferably provided with a data acquisition device for sensing and storing one or more operating characteristics associated therewith. That information can be transmitted through space to a receiver connected to a local controller for storing such information and for transmitting such information to a remote analysis system. The remote analysis system automatically updates individual records associated with each of the assets with the information received. In response to such information, the remote analysis system automatically analyzes the newly provided information and schedules maintenance as required. Information associated with the maintenance is also recorded electronically to maximize efficiency, provide historical trends, automate billing, and control inventory levels.

BACKGROUND OF THE INVENTION

The present invention relates in general to systems for tracking and managing physical assets to promote the efficient maintenance of the assets while reducing cost. In particular, this invention relates to a computer based system for automatically gathering, analyzing, and delivering information relating to the maintenance of a plurality of such assets, such as a fleet of industrial equipment, so as to maximize productivity and to reduce the operating costs and administrative burdens associated with such assets.

Many businesses operate a plurality of physical assets to assist in the performance of the daily activities that are required to produce goods or services. For example, a typical manufacturer of goods often uses a fleet of industrial equipment, such as forklifts, conveyors, machine tools, and the like, in its daily operations to facilitate the manufacture of goods for its customers. In a similar manner, a typical provider of services also often employs a plurality of assets, such as computers, communications equipment, photo imaging equipment, and the like, in its daily operations to facilitate the performance of services for its customers. Traditionally, businesses have purchased such assets for use in their facilities and have employed staff to operate and maintain the assets in furtherance of the manufacture of goods or the performance of services.

Regardless of the specific nature of the business, the operation of these assets has usually been considered to be somewhat ancillary to the core nature of the business. In other words, although the use of these assets is helpful (indeed, sometimes necessary) for the business to manufacture the goods or provide the services in a cost efficient manner, the ownership, operation, and maintenance of such assets is not, of itself, a core function of the business. Consequently, the costs associated with the procurement and utilization of such assets have not been traditionally monitored or analyzed by the business in great detail. Rather, such costs have usually been considered to be relatively fixed costs of doing business, and any management of such assets has been performed, if at all, by relatively low level employees having little training or inclination to increase productivity and reduce costs.

Obviously, many businesses have been able to produce goods and provide services without actively managing the costs of obtaining and operating these assets. However, optimization of productivity and minimization of costs are key considerations in the modern business environment. Thus, it would be desirable to provide a computer based system for automatically gathering, analyzing, and delivering information relating to the procurement and utilization of a plurality of such assets, such as a fleet of industrial equipment, so as to maximize productivity and to reduce operating costs and administrative burdens associated with such assets.

It would also be desirable to be able to provide different parties having an interest in the asset ready access to up-to-date real-time and historical access to the information associated with asset usage, maintenance, performance, and the like. For example, besides the business using the asset, there is often a third party maintenance organization that helps to maintain the asset and a leasing company acting as the true asset owner that leases the asset to the business. Because the leasing company lacks appropriate information concerning the asset, the leasing arrangement typically takes this lack of information into account as part of the lease transaction, often through a combination of both a fixed lease amount tied to the asset regardless of use, as well as a financial cushion for the benefit of the true asset owner to cover unforeseen problems associated with the asset including over-use and improper maintenance.

It is known to record and store operational parameters or fault codes associated with the asset, which may be transmitted using a communications network to a central location for the purpose of undertaking diagnostics. It is also known to use handheld devices for the real-time sharing of information with a central system. The handheld device can access information from the central system such as the status of available inventory. The central system can also provider instructions to a user of the handheld device. Finally, it is known to use various electronic systems for monitoring inventory.

However, if each of the entities involved with an asset had ready access to the same information concerning the asset, and the ability to update that information as well as related information associated with maintenance of the asset on a real-time basis, the involved parties may be willing to share an increased portion of the financial risk/reward associated with the usage, maintenance, performance, or the like with respect to the asset. With appropriate objective information it may be possible to distribute a portion of the responsibility to other responsible third parties including the asset manufacturer or supplier, and asset maintenance organization.

SUMMARY OF THE INVENTION

This invention relates to a computer based system for automatically gathering, analyzing, and delivering information relating to the procurement and utilization of a plurality of such assets, such as a fleet of industrial equipment, so as to maximize productivity and to reduce operating costs and administrative burdens. Each of the assets is preferably provided with a data acquisition device for sensing and storing one or more operating characteristics associated therewith such as a fault code generated by the asset when there is a maintenance problem or when routine maintenance is required in accordance with predetermined criteria. That information can be transmitted through space to a receiver connected to a local controller for storing such information and for transmitting such information over the Internet to a remote analysis system. The remote analysis system automatically updates individual records associated with each of the assets with the information received from the Internet. In response to such information, the remote analysis system automatically analyzes the newly provided information and generates reports regarding scheduled maintenance, warranty coverage, and other management information. These reports can be transmitted back over the Internet to an administrative controller for review by one or more persons responsible for managerial review. Additionally or alternatively, the remote analysis system can automatically post such reports on a website and, thus, be made available to one or more of such persons upon request.

Not only can the information be provided to an administrative controller, but it can be provided to third parties such as maintenance organizations, asset manufacturers or suppliers, and leasing companies. By providing up-to-date real-time and historical information concerning the asset, such third parties are willing to share the risk of the asset's usage, maintenance, and performance through creative arrangements with the asset user. A maintenance organization, for example, may be willing to enter into a fixed maintenance contract when it has the ability to readily detect adverse maintenance trends regarding an asset and is given the ability to take pro-active steps to address problems before they become major. The cost-savings associated with such a pro-active approach by an expert may be shared to the benefit of the business and the maintenance organization. Similarly, a leasing company that can reduce ownership risk through asset monitoring and appropriate asset utilization is more likely to agree to a hybrid minimum term payment and asset usage billing system or even a usage based billing system with no minimum payments.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings, there is illustrated inFIG. 1a schematic block diagram of a prior art computer based system, indicated generally at10, for tracking and managing a plurality of assets, several of which are indicated generally at11. The assets11are illustrated as being a plurality of pieces of movable industrial equipment, such as a plurality of conventional forklifts or similar machinery, used in the manufacture of goods in a typical factory environment. However, the prior art method could be used to track and manage any type of asset11, such as those described above, used in the manufacture of goods or the performance of services. The basic structure and operation of each of the forklifts11are well known in the art and, therefore, require no discussion for a complete understanding of this invention.

The prior art system10further included a remote analysis system, indicated generally at12, for tracking and managing the assets11. The remote analysis system12was completely separate and apart from the assets11and included an analysis controller13having one or more input devices14and one or more output devices15connected thereto. The remote analysis system12could be embodied as any conventional electronic controller, such as a microprocessor-based computer device. The input device14was embodied as a keyboard or other conventional mechanism for manually inputting data in electronic form to the analysis controller13for processing in the manner described below. The output device15was embodied as a printer or other conventional mechanism for generating a hard copy of the management information generated by the analysis controller13in the manner described below.

Referring now toFIG. 2, there is illustrated a flow chart, indicated generally at20, of a prior art method for tracking and managing the assets11in accordance with the prior art computer based system10illustrated in FIG.1. Throughout this discussion, reference will be made to a first person or entity that owns or operates the assets11that are being tracked and to a second person or entity that is responsible for tracking the management information relating to such assets11. Notwithstanding this, it will be appreciated that a single person or entity may not only own and operate the assets11, but also track the management information relating thereto.

In an initial step21of the prior art method20, a record was created for each individual asset11by the person or entity responsible for tracking such assets, such as one of the forklifts11illustrated in FIG.1. This record was created electronically within the analysis controller13by means of the input device14and included a variety of information that was desired to be tracked for management purposes. First, the record included information that uniquely identified the particular asset11being tracked. Such identification information included, for example, data regarding the make, model, year, and serial number of the asset11, plus any customer-assigned identification number. Second, the record included information that related to the operational characteristics of the particular asset11being tracked, such as the physical requirements or limitations of the asset11(mast height, load capacity, type of tires for the forklift11, for example), the type of fuel used, and the period of time or usage between the performance of periodic maintenance. Third, the record included information relating to the acquisition of the asset11by the owner or lessee thereof. Such acquisition information included, for example, the type and date of acquisition (purchase or lease, for example), the name of the owner or lessee, the location at which the asset11is used, the expected amount of usage of the asset11(one, two, or three shifts, for example), and the cost of the acquisition or lease. Furthermore, the record included an area for adding additional information or remarks as desired.

In a second step22of the prior art method20, it was determined whether a maintenance invoice had been received by the person or entity responsible for tracking the assets11. Typically, a maintenance invoice was a written communication that was generated created by or at the request of the person or entity that owned or operated the assets11. The maintenance invoice was usually generated upon the occurrence of an event relating to the particular asset11and generally contained information regarding the status of one or more operational characteristics of that asset11. For example, after a particular forklift11had been operated by the person or entity that owned or operated the asset11for a particular period of time, it would require the performance of some maintenance. This maintenance may, for example, have constituted routine preventative service as a result of the elapse of a predetermined period of time or usage. Alternatively, such maintenance may have constituted non-routine service, such as a repair of a mechanical breakdown. In either event, a maintenance invoice was generated as a result of the performance of that maintenance. The occurrence of other events related to the assets11could also result in the generation of maintenance invoices. In many cases, the maintenance was performed by a maintenance organization having specialized knowledge of asset11and its long-term care.

Regardless of the nature of the event that caused them to be generated, the maintenance invoices were generated in hard copy form and contained therein certain information that was desired to be tracked for management purposes, such as the date and nature of the maintenance that was performed, the amount of usage of the asset11as of the date of such maintenance, and the cost of such maintenance. To perform the second step22of the prior art method20, the maintenance invoices were required to be physically delivered from the location where the assets11were being used or serviced to the location of the analysis controller13or to the location of the input device14of the analysis controller13. By physically delivered, it is meant that the maintenance invoice was transmitted in a non-electronic, hard copy form (including, for example, by facsimile) from the person or entity that owned or operated the asset11(and who performed, or had performed, the maintenance on the asset11) to the person or entity responsible for tracking the assets11.

As shown inFIG. 2, the prior art method20continuously repeated step22until it was determined that a maintenance invoice had been received by the person or entity responsible for tracking the assets11. When that occurred, the prior art method branched from the step22to a step23, wherein the record contained in the analysis controller13relating to the particular asset11was updated with the information contained in the maintenance invoice. This step23was accomplished by utilizing the input device14to manually enter the information contained in the maintenance invoice into the record relating to the particular asset11contained in the analysis controller13.

Based upon the updated information contained in the record of the asset11, the analysis controller13was programmed to perform a fourth step24of the prior art method20, wherein it was determined whether a sufficient period of time or usage had elapsed as to trigger the performance of periodic routine maintenance for that asset11. Typically, such determination was made by determining the amount of the elapsed time or usage of the asset11(by comparing the most recent indication of the date or amount of usage of the asset11with the previous date or amount of usage contained in the record stored in the analysis controller13), and by comparing such elapsed time or amount of usage with a predetermined standard (also contained in the record of the asset11stored in the analysis controller13). If it was determined that a sufficient amount of elapsed time or amount of usage had occurred, the method20branched from the step24to a step25, wherein a hard copy maintenance report was generated by the output device15. Then, in step26of the prior art method20, the maintenance report generated in the step25was physically delivered from the person or entity responsible for tracking the asset11to the person or entity that owned or operated the asset11. The maintenance report advised the person or entity that owned or operated the asset11that the time had arrived for the performance of periodic routine maintenance.

Thereafter, the prior art method20entered a step27, wherein it was determined whether a predetermined period of time had elapsed to generate a periodic management report covering some or all of the assets11being tracked. Alternatively, if in step24of the prior art method20, it was determined that a sufficient amount elapsed time or amount of usage had not yet occurred, the method20branched directly from the step24to the step27. In either event, such management reports were typically generated on a monthly basis. Thus, if the end of the month had occurred, the prior art method20branched from the step27to a step28wherein a hard copy management report was generated by the output device15. Then, in step29of the prior art method20, the management report generated in the step28was physically delivered from the person or entity responsible for tracking the asset11to the person or entity that owned or operated the asset11The management report advised the person or entity that owned or operated the asset11of the status of some or all of the assets11that were being tracked, allowing various management oversight and decisions to be made at that time. Thereafter, the prior art method20returned from the step29to the step22, wherein it was determined whether a maintenance invoice had been created by or at the request of the person or entity that owns or operates the assets11and was physically delivered to the person or entity responsible for tracking the assets11. Alternatively, if in step27of the prior art method20, it was determined that a predetermined period of time had not yet elapsed to generate a periodic management report covering some or all of the assets11being tracked, then the method20returned directly from the step27to the step22.

Referring now toFIG. 3, there is illustrated schematic block diagram of a computer based system, indicated generally at30, for tracking and managing a plurality of assets, indicated generally at31, in accordance with this invention. As with the prior art system10described above, the illustrated assets31are represented as a plurality of pieces of movable industrial equipment, such as a plurality of conventional forklifts or similar machinery, used in the manufacture of goods in a factory environment. However, the method of this invention can be used to track and manage any type of asset31, such as those described above, used in the manufacture of goods or the performance of services.

As above, the basic structure and operation of each of the forklifts31are well known in the art, and, therefore, require no discussion for a complete understanding of this invention. However, unlike the forklifts11of the prior art system10, a data acquisition device32is provided on each of the forklifts31for sensing and storing one or more operating characteristics of the associated forklift31. The basic structure and operation of each of the data acquisition devices32are conventional in the art. For example, each of the data acquisition devices31may be embodied as an electronic processor or controller that can sense or be otherwise responsive to one or more operating conditions of the associated forklift31. Each of the data acquisition devices31can be responsive to any desired operating conditions of the forklift31that might be considered important in making effective management decisions regarding the operation of the forklift31. Such desired operating conditions can, for example, include the time duration of use (and non-use), distances traveled, the extent of fork usage, the nature of hydraulic system utilization, and the like. More typically for industrial assets, the most importance criteria is time duration of use. The sensed operating conditions of the forklifts31are preferably stored at least temporarily in a memory of the data acquisition device32for subsequent communication to a remote analysis system, indicated generally at50, for analysis in the manner described in detail below. Thus, the data acquisition devices32sense and store the desired operating conditions for each of the forklifts31during use.

Each of the forklifts31is further provided with a transmitter33or other communications system for transmitting the acquired data from the data acquisition device32to the remote analysis system50for analysis. Each of the transmitters33may be embodied as any conventional device for transmitting the acquired data to the remote analysis system50, such as a hard-wired communications interface. However, as is well known, each of the forklifts31is a movable vehicle that is capable of traveling extensively throughout the particular environment in which it is used. To facilitate the transmission of the acquired data, therefore, the transmitter33is preferably embodied as a wireless communications system, such as represented by an antenna34. The transmitters33and the wireless communications systems34can be embodied as conventional radio frequency transmitters provided on each of the forklifts31that transmit electromagnetic signals. However, other well known forms of wireless communication, such as those utilizing light or sound, may be used in lieu of a radio frequency transmitter.

The wireless communications systems34are adapted to transmit signals that are representative of the sensed operating conditions of the forklifts31through space to a receiver35. In contrast to the forklifts31that can travel extensively throughout the environment in which they are operated, the receiver35is preferably provided at a fixed location within that environment. If desired, a plurality of such receivers35may be provided at different locations within the environment in which the forklifts31are operated. As the forklifts31move about the environment during use, they will occasionally pass by or near the receiver35. When this occurs, the receiver35receives the data transmitted from the respective data acquisition units32. The receiver35is also conventional in the art.

Preferably, the data acquisition units32and the receivers35are in bi-directional communication with one another. One advantage of such bi-directional communication is that the data acquisition unit32can send out a query signal on a predetermined basis to be received by the receiver35when the two units32and35are sufficiently close to communicate reliably with one another. Thus, when the data acquisition unit32contacts the receiver35, the receiver35can send a first signal back to the data acquisition unit32to instruct it to begin transmitting the acquired data. At the completion of the data transfer, the receiver35can send a second signal back to the data acquisition unit32to acknowledge the receipt of the transmitted data. A conventional error checking algorithm can be used to confirm the accuracy and completeness of the transmitted data and, if necessary, request a re-transmission thereof.

Another advantage of such bi-directional communication is that data in the form of new commands, program updates, instructions, and the like can be sent to the data acquisition units32from the receiver35. In some instances, such as when a data acquisition unit32is in generally continuous communication with a receiver35, a user of the forklift31can be prompted to provide certain information for transmission to the receiver35for further analysis.

The receiver35is connected to a local controller36. The local controller36is also, of itself, conventional in the art and may be embodied as an electronic controller that is adapted to receive and store at least temporarily the data from each of the receivers35. Alternatively, if the assets31are fixed in position, such as in the case of a plurality of stationary machines used in a manufacturing environment, the receiver35or receivers35may be provided on movable structures that move about the environment to receive the information transmitted therefrom. In either event, it is desirable that the local controller36acknowledge receipt of the information transmitted from the data acquisition devices32, allowing the data acquisition devices32to delete the transmitted information and begin storing newly acquired information. A combined system including the data acquisition device32, the transmitter33, the wireless communications system34, the receiver35, and software for operating the local controller36to gather and report data is commercially available, such as from I.D. Systems, Inc. of Hackensack, New Jersey or Requip (formerly SXI).

In a preferred embodiment, the various elements located in an asset31are hardwired into the electrical system of the asset to minimize the possibility of undesirable failure or tampering.

Thus, after the forklifts31have been operated for a period of time, the local controller36will have gathered and stored therein a certain amount of information regarding the individual operating characteristics for each of the forklifts31. The local controller36is programmed to periodically transmit the information stored therein to the remote analysis system50for analysis. This can be accomplished by providing the local controller36with a conventional modem37or other communications device that can convert the stored information into a format that is compatible for transmission through an electronic communications network, such as the internet40. As is well known, the Internet40is a digital electronic communications network that connects computer networks and organizational computer facilities around the world. Access to the Internet40can be easily obtained in most locations through the local telephone lines or by similar means.

The system30of this invention may be used to track and manage a plurality of assets31located at any desired physical location. Additionally, the system30of this invention may be used to track and manage assets31located at a plurality of different physical locations, as suggested by the dotted lines in FIG.3. Each different physical location can be provided with one or more receiver35, a local controller36, and a modem37to connect the system30to the Internet40.

As mentioned above, the sensed operating conditions of the forklifts31are intended to be transmitted to the remote analysis system50for analysis. Referring again toFIG. 3, it can be seen that the remote analysis system50includes an analysis controller51that is connected to communicate through the internet40by means of a modem52or similar communications device. If desired, a communications server51a may be connected between the analysis controller51and the modem52. The communications server51ais provided to selectively receive and organize the information from each of the local controllers36for delivery to the analysis controller51. The analysis controller51can be embodied as any conventional electronic controller that is capable of receiving the sensed operating conditions of the forklifts31and for processing that information in a desired manner described in detail below. Ideally, the sensed operating conditions of the forklifts31are used to automatically generate and analyze management reports relating to the procurement and utilization of a plurality of the forklifts31to maximize productivity and to reduce operating costs and administrative burdens. An input device53and an output device54, both of which are conventional in the art, may be connected to the analysis controller51.

As also shown inFIG. 3, one or more administrative controllers55(only one is illustrated) can be connected to the internet40through respective modems56or similar communications devices. Each of the administrative controllers55can also be embodied as any conventional electronic controller that can request and receive information from the remote analysis system50through the Internet40. In a manner that is described in detail below, the administrative controllers55are provided to request and receive the management information generated by the remote analysis system50. If desired, the local controller36can also function as an administrative controller55, although such is not necessary. An input device57and an output device58, both of which are conventional in the art, may be connected to the administrative controller55.

Referring now toFIGS. 4A through 4C, there is illustrated a flow chart, indicated generally at60, of a method for tracking and managing the assets31in accordance with this invention using the computer based system30illustrated in FIG.3. Throughout this discussion also, reference will be made to a first person or entity that owns or operates the assets31that are being tracked and to a second person or entity that is responsible for tracking information relating to such assets31. As above, it will be appreciated that a single person or entity may not only own and operate the assets31, but also track the information relating thereto.

In an initial step61of the method60, a record is created for each individual asset31by the person or entity responsible for tracking such assets, such as one of the forklifts31illustrated in FIG.3. The record can be created electronically within the analysis controller51by means of the input device53and can include a variety of information that is desired to be tracked for management purposes, including all of the information described above in connection with the forklifts11and the analysis controller13. Additionally, the record can further include information regarding the nature and time duration of a warranty provided by the manufacturer or supplier of the assets31. Such warranty information can be used in the manner described in further detail below to automatically determine whether the responsibility for the maintenance being performed on the asset31, either in whole or in part, should rest with the manufacturer or the supplier of the asset31or with the owner or user of the asset31.

In a second step62of the method60, it is determined whether a maintenance invoice has been received by the person or entity responsible for tracking the assets31. Such maintenance invoices can be generated and delivered in the same manner as described above. If it is determined that a maintenance invoice has been received by the person or entity responsible for tracking the assets31, the method branches from the step62to a step63, wherein the record contained in the analysis controller51relating to the particular asset31is updated with the information contained in the maintenance invoice in the same manner as described above. Next, the method enters a step64wherein the record contained in the analysis controller51relating to the particular asset31is updated with information from the internet40. Alternatively, if it is determined that a maintenance invoice has not been received by the person or entity responsible for tracking the assets31, the method branches directly from the step62to the step64.

As discussed above, the local controller36will have gathered and stored therein a certain amount of information regarding the individual operating characteristics for each of the forklifts31. The local controller37is programmed to periodically transmit the information stored therein to the remote analysis system50for analysis. The analysis controller51can include a memory circuit for storing this information from the local controller36. The transmission of the information from the local controller36to the analysis controller51can be performed in real time, upon occurrence of predetermined events (such as the gathering of a predetermined amount of information), or at predetermined time intervals. In any event, the record contained in the analysis controller51is automatically updated with the latest information regarding the status of the asset31, without any human intervention.

Based upon the updated information contained in the record of the asset31, the analysis controller51next determines whether a sufficient period of time or usage has elapsed as to trigger the performance of periodic routine maintenance for that asset31. This determination can be made in the same manner as described above in connection with24of the prior art method20. If it is determined that a sufficient amount elapsed time or amount of usage had occurred, the method60branches from the step65to a step66, wherein an electronic maintenance report is generated. If desired, a hard copy of the maintenance report can also be generated by an output device54connected to the analysis controller51. Then, in step67of the method60, the electronic maintenance report generated in the step66is delivered from the person or entity responsible for tracking the asset31to the person or entity that owns or operates the asset31through the Internet40. As above, the maintenance report can advise the person or entity that owns or operates the asset31that the time had arrived for the performance of periodic routine maintenance. Moreover, if a specific fault code has been Alternatively, the maintenance report55can be delivered to a specialized maintenance organization responsible for maintenance of the assets31. The electronic maintenance report can, for example, be delivered through the Internet40to one or more of the administrative controllers55as desired. Alternatively, or additionally, the electronic maintenance report can be delivered through the Internet40to one or more of the local controllers36. Also, in step68of the method60, the electronic maintenance report generated in the step66is posted on a website maintained on the Internet40. The website may be maintained either by the person or entity responsible for tracking the asset31or by the person or entity that owns or operates the asset31through the Internet40. As opposed to the direct electronic delivery of the maintenance report to a particular person or group of persons contemplated in the step67, the step68contemplates that the maintenance report is made available to such person or group of persons at their request over the Internet40.

Thereafter, the method60enters a step69, wherein it is determined whether any maintenance that has been performed on the asset31occurred within the warranty period provided by the manufacturer or supplier. Alternatively, if in the step65of the method60, it was determined that a sufficient amount elapsed time or amount of usage had not yet occurred, the method60branches directly from the step65to the step69. In either event, this determination can be made by comparing the date of service or amount of usage of the asset31with the warranty information contained in the record for that asset31contained in the analysis controller51. If it is determined that service on the asset31occurred within the warranty period, the method60branches from the step69to a step70, wherein an electronic warranty report is generated. If desired, a hard copy of the warranty report can also be generated by the output device54connected to the analysis controller51. Then, in step71of the method60, the electronic warranty report generated in the step70is delivered from the person or entity responsible for tracking the asset31to the person or entity that owns or operates the asset31through the Internet40. As above, the warranty report can advise the person or entity that owns or operates the asset31that the service performed on the asset31should be paid for by the manufacturer or supplier of the asset31. The electronic warranty report can, for example, be delivered through the Internet40to one or more of the administrative controllers55as desired. Alternatively, or additionally, the electronic warranty report can be delivered through the Internet40to one or more of the local controllers36. Also, in step72of the method60, the electronic warranty report generated in the step70is posted on a website maintained on the Internet40. The website may be maintained either by the person or entity responsible for tracking the asset31or by the person or entity that owns or operates the asset31through the Internet40. As opposed to the direct electronic delivery of the warranty report to a particular person or group of persons contemplated in the step71, the step72contemplates that the warranty report is made available to such person or group of persons at their request over the Internet40.

Thereafter, the method60enters a step73, wherein it is determined whether a predetermined period of time has elapsed to generate a periodic management report covering some or all of the assets31being tracked. Alternatively, if in step69of the method60, it was determined that a sufficient amount elapsed time or amount of usage had not yet occurred, the method60branches directly from the step69to the step73. In either event, such management reports are typically generated on a monthly basis. Thus, if the end of the month has occurred, the method60branches from the step73to a step74, wherein an electronic management report is generated. If desired, a hard copy of the management report can also be generated by the output device54connected to the analysis controller51. Then, in step75of the method60, the electronic management report generated in the step74is delivered from the person or entity responsible for tracking the asset31to the person or entity that owns or operates the asset31through the Internet40. As above, the management report can advise the person or entity that owns or operates the asset31of the same information as the management reports discussed above. The electronic management report can, for example, be delivered through the Internet40to one or more of the administrative controllers55as desired. Alternatively, or additionally, the electronic management report can be delivered through the Internet40to one or more of the local controllers36. Also, in step76of the method60, the electronic warranty report generated in the step74is posted on a website maintained on the Internet40. The website may be maintained either by the person or entity responsible for tracking the asset31or by the person or entity that owns or operates the asset31through the Internet40. As opposed to the direct electronic delivery of the management report to a particular person or group of persons contemplated in the step75, the step76contemplates that the management report is made available to such person or group of persons at their request over the Internet.

FIG. 4Cdemonstrates an additional functional aspect of method60using the inventive system. In addition to determining whether a maintenance invoice has been received, if scheduled maintenance has been performed, and determining the party responsibility for certain maintenance activities, it is possible to poll asset data points at point76from an analysis controller database78associated with one or more discrete analysis controllers51that may be associated with one or more businesses. A plurality of databases78are shown. One or more separate databases may be combined to form a logical database78. When a maintenance organization has access to various asset fleets of the same type or make of equipment, it may be beneficial to analyze the relevant information using a larger available knowledgebase of information to analyze appropriate trends. By analyzing the data points, certain maintenance trends can be analyzed and problems can be anticipated before they affect asset utilization. For example, if it turns out that asset31has a tendency to need new batteries after a certain period of usage; the need for such batteries can be anticipated and stocked on site when appropriate to facilitate maintenance. As shown inFIG. 4C, once the various trends have been analyzed for assets31, at decision point80it is determined whether preventative maintenance is required. If it is required, the maintenance is performed as shown at point82and the information is stored in database78. The asset data points are then analyzed again until it is determined that no further preventative maintenance is required. Then the system terminates at point84. Thus,FIGS. 4A through 4Cillustrate the use of critical information from assets31to perform maintenance and to provide a methodology for providing access to information by various third parties.

FIG. 5illustrates the beneficial interrelationships that promote efficiency by having various parties associated in some way with an asset31in one or two-way communication with analysis controller51either by way of administrative controller55, reports71or75, web site postings electronic mail, or the like. As already discussed above, asset31provides usage and performance data that is stored in the asset controller51according to certain predetermined criteria important for that asset. As also discussed above, a maintenance organization86both receives and provides information to database78. While business90may provide its own maintenance of assets90, for the discussion a separate maintenance organization is illustrated.

Warranty information as shown by steps70through72ofFIG. 4Bis of particular interest to the asset manufacturer or supplier88. While it may not be appropriate for a supplier88to be able to alter information in database78, the ability to quickly and accurately collect information concerning warranty obligations and the like is of particular benefit to all of the parties. For example, warranty issues may be caught more quickly, ultimately reducing asset cost and operation while simultaneously promoting asset up time. The ability of the asset user90to analyze and administer assets31has also been discussed in detail. However, key advantages also result by allowing the owner of asset31to analyze key data associated with asset31. In the illustrated embodiment, it is assumed that the owner of the asset31is a separate asset owner92such as a leasing company, as opposed to business90itself, although this is not required.

The advantages of an asset owner92having at least one and possibly two-way access to the real-time and historical information stored in analysis controller database78as well as the ability to communicate with supplier88, maintenance86, and business90, is illustrated in sub-system98illustrated in FIG.6. Sub-system98is activated by the asset owner92using data from database78, but typically utilizing its own lease administration and billing systems. In many cases it is also using its own fleet analysis and management systems, which are typically aggregating information from a number of different fleets associated with a plurality of businesses90. These various systems, one or more of which may be used independently or in concert, are collectively shown at point99. As noted above, web-site access, generated reports, analysis controllers51, and administrative controllers55provide exemplary access points for pulling asset information from system30.

An asset owner92and an asset user such as business90share the common interest in maximizing efficiency by taking into account such variables as asset usage and asset costs. The more information that is available, the more likely that efficiency is maximized. In traditional leasing relationships involving non-fixed or movable assets such as forklifts where minimal asset utilization information is available, the burden of determining the point of maximum efficiency typically rests with business90, since it has control over the asset. Therefore, a leasing company92typically enters into a lease arrangement where a fixed lease amount is paid in periodic payments by business90over the life of the lease. At best, only minor flexibilities are provided. When leasing company92regains control of an asset31at the end of the lease term, there is uncertainty concerning the condition of the asset. This uncertainty also typically rests with business90in the form of a financial cushion incorporated into the leasing relationship.

However, such uncertainty is minimized in the present invention. As shown at point100, asset owner92is able to analyze the various desired objectively generated asset data points associated with an asset31. As noted above, these data points can include the time of asset usage within a fixed time period, distance traveled, and certain performance parameters associated with the particular asset (e.g., hydraulic system usage or fork usage for fork lifts). As noted above, in practice, for industrial assets the time of use is the most important single data point. Then, as shown at point102, asset owner92may analyze maintenance considerations. For example, a major routine overhaul as compared to a system failure can be analyzed. Then at point104, the asset owner92can compare the raw data from the asset with maintenance conducted during the same time period. By comparing the raw data with maintenance considerations, the owner is able to analyze the asset utilization under the control of business90if maintenance organization86and supplier88are different third parties. For example, the asset owner92can determine that an asset31has been used very little during the time period, even allowing for maintenance. Alternatively, the owner may determine that the asset is being used continuously when not undergoing maintenance, possibly suggesting that additional assets may be appropriate to reduce overall maintenance stress on the pre-existing asset.

Additional information can be analyzed by the asset owner as shown at decision point106. Typically, the information includes data associated with other parties having access to database78. As shown at point108, for example, the asset owner92can evaluate the maintenance relationship with maintenance organization86. If the relationship has been very positive, an appropriate incentive may be provided to the organization in the form of shared cost savings. Alternatively, if the relationship has been negative, an appropriate penalty may also be implemented. The same considerations are available if business90acts as its own maintenance organization86.

Similarly, the asset owner92may evaluate its relationship with the asset supplier88as shown at point110. The information may affect asset payments from the owner to the supplier or the future relationship of the parties.

These various advantages are applicable even if asset owner92and business90are the same entity. However, more typically with industrial equipment, asset owner92is different than asset user90, where the two parties have entered into a lessor/lessee relationship. In such a case, the information in database78may be used to mutually maximize the relationship between the asset owner92and the business90. With appropriate safeguards asset owner92may be willing to share in a greater portion of the risk associated with the utilization of asset31in determining a lease rate based on an analysis of each user fleet or individual asset as shown at point112. Most significantly, rather than entering into a traditional fixed lease amount as noted above, asset owner92may be willing to enter into a5hybrid lease arrangement wherein the lease charge may be a combination of one or more of the following elements: 1) a minimum payment that has to be made if asset utilization is below a pre-determined minimum threshold; 2) a usage based-payment that is made if usage is above the pre-determined minimum threshold and below a pre-determined maximum threshold; 3) a penalty payment or surcharge is made if utilization is higher than the predetermined maximum threshold; and 4) payments/rewards based on incentive issues such as asset re-allocation or timely maintenance.

The decision of whether to use usage-based billing based on one or more objective criteria based on an analysis of asset utilization is shown at decision point114. The decisions to charge either a minimum payment if a certain usage level is not met, or to charge a usage penalty above a maximum appropriate usage level, are shown by decision points116and118respectively. Thus, a variable-amount lease may be developed based on an analysis of objective criteria that is based in large part on the actual portion of an asset's life that is consumed by the asset user (e.g., usage hours). In a preferred embodiment, the analysis is based on a pre-determined usage/pricing matrix in combination with actual usage for a specified time period. Once a level of maximum efficiency has developed, leasing will typically be primarily, if not solely, based on asset usage billing.

Through the use of the innovative leasing arrangement based on improved information availability to asset owner92, the expenses of an asset user such as business90can be more accurately aligned with usage and asset value consumption. More operational flexibility is provided to business90. When leasing is based predominantly on asset usage billing, a business90is able to adopt true off-balance sheet financing (i.e., the business is not required to note a financial obligation even in the footnotes of various financial reports as opposed to standard off-balance sheet leasing where a company must disclose the lease in footnotes even if the lease does not show up on the balance sheet). At the same time, asset owner92, can collect information from a variety of sources to maximize its relationships with its own vendors and customers to the benefit of all related parties by minimizing inefficiencies and providing appropriate accountability with maximum accuracy and validity tied to a minimal likelihood for mistakes, misinformation, or even fraud.

These various factors can be adjusted dynamically by the asset owner92as a knowledge base is collected within its internal systems99and based on the actions of the other related parties. For a sophisticated asset owner with numerous fleets, it can conduct appropriate analyses over all of its fleets to determine certain trends, which it may advantageously use.

For example, if supplier88or maintenance organization86is responsible for abnormally low asset utilization as opposed to actions within the control of business90, then the risk associated with these possibilities can be shared between asset owner92and various affected businesses90and transferred in some fashion to the responsible party. Thus, in a more preferred embodiment of the invention, asset usage is adjusted for maintenance considerations if business90is not responsible for its own maintenance.

As shown at point120, once the readily available information is analyzed in view of the business relationship between an asset owner92and a business90, an invoice and billing module associated with the asset owner's own internal systems99is invoked that generates an appropriate invoice that is sent by the asset owner to the business for payment and subsystem98terminates at point122. In a preferred embodiment, once sub-system98is developed for a particular situation, and in the absence of an extraordinary event, invoicing is automated based strictly on the objective criteria developed with minimal outside involvement.

A key advantage of the present invention is that real-time data is collected by data acquisition device34and timely transmitted to local controller36for transmission to database78of analysis controller51. If incomplete or limited data representing only a small portion of the appropriate asset data points are transmitted, then appropriate decisions cannot be made to maximize asset utilization. For example, in the case of forklifts, both time of usage and distance traveled help provide information concerning asset utilization and maintenance considerations.

Thus, the computer based system30, including sub-system98, of the present invention provides a superior method for tracking and managing the assets31than the prior art system10. First, by providing the assets with the data acquisition devices32and the communications system33and34, the operational characteristics and other information regarding the assets31is automatically sensed and transmitted to the analysis controller51on a real time basis, without requiring human intervention or assistance. Second, the analysis controller51is programmed to analyze such information as it is received and to automatically generate maintenance and warranty reports in response thereto. Third, all of the reports generated by the analysis controller51are automatically delivered to the appropriate persons through the Internet40, either directly to one or more of the administrative controllers55or by posting on a web site, electronic mail or similar mechanisms. Fourth, as shown by subsystem98, the information can be used to maximize asset usage efficiency. As a result, the computer based system30facilitates the gathering, analyzing, and delivering of information relating to the procurement and utilization of the assets31so as to maximize productivity and to reduce operating costs and administrative burdens to the benefit of all parties having a relationship with the asset and an interest in its performance.

The providing of maintenance to an asset31is illustrated in further detail in FIG.7. In addition to determining whether it is necessary to provide scheduled maintenance as noted at step65ofFIG. 4A, changes in operational parameters associated with asset31as shown at point150may result in the generation of a specific fault code if a maintenance problem is detected that requires a more expeditious response. The fault code may be generated by the asset itself using one or more sensors associated with operational parameters of asset31as shown by point152and communicated to the data acquisition device32. In addition, analysis controller51may analyze the raw operational data received from the asset31and compare it with analysis controller database78including the history of the specific asset31as well as the history of similar assets from which maintenance trends may be determined as discussed with respect toFIG. 4Cabove. Based on an analysis of such trends, proactive lower cost maintenance can be timely performed that results in the avoidance of higher cost maintenance at a later date, which happens in the absence of real-time information available for review and analysis.

A fault code may even be generated based on the actions of the asset operator. In a preferred embodiment of the invention, an electronic checklist154is completed by the asset operator on a regular basis, which may include information concerning asset performance that is more detailed than that available from a review of raw operational parameters. In accordance with OSHA requirements, for example, at the end of each shift, a forklift operator must complete a checklist concerning the performance of the asset during the shift. Some of the questions associated with checklist154are directed to maintenance issues. Therefore, in a preferred embodiment of the invention, checklist154would be completed electronically at the asset31, and transmitted by way of the data acquisition device32to analysis controller51as discussed above. The information would be analyzed to determine if an OSHA/repair need is identified. Preferably, the analysis is automated in accordance with a comparison of the operational status with pre-determined rules. For example, if a question asks if there is a hydraulic leak for a forklift and the answer is “yes”, then maintenance would be appropriate.

Once it is determined that maintenance of some type is required as shown at point156based on an analysis of the operational status of asset31, a maintenance report66is generated as also shown in FIG.4A and made available electronically at point67′ such as by the Internet or by posting on a website as also shown in FIG.4A. The use of electronic mail, or the providing of real-time access to the raw data stored within database78by the maintenance organization86, shown inFIG. 5, is also possible to generate the maintenance report66. An advantage of providing a maintenance organization86real-time access to the raw data representing the operational status of asset31is that it may develop specialized analysis tools based on its own expertise in maintenance, resulting for example in the creation of specialized rules for use in automatically analyzing raw data in determining whether maintenance is required, minimizing the need for manual review and determination.

In a preferred embodiment, the priority of the proposed maintenance required158is noted on the maintenance report. For example, critical maintenance issues should take precedence over routine issues. Moreover, the system generally institutes an approval process as shown at point160. For example, if the proposed maintenance is related to warranty work such as noted with respect to step69ofFIG. 4B, the manufacturer or supplier should approve the maintenance. If a lessee is responsible for the proposed maintenance, it should approve the maintenance before it is performed. In some cases, the maintenance organization86itself approves the maintenance, such as when it has a contract that involves pre-payment of particular maintenance. Finally, as shown at point162, in some cases it may be desirable to have the lessor or owner of the asset have the ability to review and override any refusals to perform maintenance since it has the ultimate responsibility for asset31. If no approvals are given, the process is terminated at point164. A review of any automated rules that generated a request for maintenance approval may also be appropriate. When maintenance approval is rejected, any automated rules that generated the original maintenance request can be finetuned by including the results of the approval process. Over time, almost all maintenance requests should be generally approved. Information regarding approval is stored in database78.

For preventative maintenance, it is expected that pre-approval will generally be granted by the necessary parties based on prior agreement as to the nature and timing of such maintenance.

Once maintenance has been approved, a work order166is generated. As shown inFIG. 8, work order166is sent electronically to appropriate maintenance personnel that contains all of the critical operating data required to effectively schedule and carry out the maintenance. Typically, for example, the data includes hour meter reading, any fault codes, asset identification criteria, operator of record, contact information, and asset location. Moreover, based on information contained within the fault code or retrieved from the knowledgebase, information concerning anticipated parts may also be provided as well as the nearest location from where they may be retrieved (e.g., at a customer location, or from a local servicing dealer). Finally, the work order166preferably contains the past recent history of the particular asset31so that the mechanic can use this information to expedite maintenance.

In a preferred embodiment of the invention, the work order166is transmitted electronically to a handheld device168associated with specific maintenance personnel assigned to carry out the maintenance. Moreover, in a more preferred embodiment of the invention, the handheld device168is in real-time two way communication with analysis controller database78. Thus, under appropriate circumstances the handheld device168can access such things as dealer billing systems, inventory listings, customer work order approval records, and fleet management information. Rather than having the work order include the past recent history of the asset31to be serviced, it is possible to use the two way communication link to request the necessary history when advantageous to do so.

Once the maintenance is completed, handheld device168is used to update database78as shown at point170, including labor information and an identification of any parts required to effect a repair. If not already clear based on the contents of database78, the inventory location from which any parts were pulled should also be provided. Ideally, the information is transmitted on a real-time basis from the handheld device168. Alternatively, however, the information can be transmitted upon routine synchronization of the handheld device with database78. It is also possible to manually enter the information into the database78.

The maintenance information is passed to database78where it may be used to5generate maintenance tracking reports172, and comprehensive invoices174listing both labor and part costs. Since the information is integrated with pre-existing asset information, no rekeying is required. Moreover, as noted above with respect toFIG. 4C, the complete maintenance history of a particular asset or class of assets may be reviewed and analyzed in detail for specific trends of interest.

In addition, when parts are used, as shown at point176, the system preferably permits comparison of the parts used with existing inventory for the specified parts storage location. Based on maintenance trends associated with a class of assets31or a specific asset31, it is possible for the system to automatically order replacement parts for an inventory location if the number of parts in a particular inventory fall below a pre-determined threshold as shown at points178and180. The threshold is calculated at least in part based on an analysis of the prior maintenance of both the asset31and the class of assets associated with the asset. Other factors may include the age of the class of assets, the time of the year, usage trends and the like. As one example, in the winter different parts may be required as opposed to in the summer. As another example, more tires may be required for a forklift asset if a number of the assets are reaching a preventative maintenance stage where tires have to be replaced. The system terminates at point182.

Thus, the inventive system provides a number of advantages for maintenance. For example, through the use of electronic information transmission and analysis, maintenance information is transferred and available real-time for review and for the initiation of necessary actions such as approval, the tracking of performed maintenance, the ordering of replacement parts to replenish depleted inventories, and automatic invoice generation. Since asset31communicates its own maintenance needs in consultation with an appropriate knowledgebase associated with database78, human intervention is minimized. As more information is gathered over time, the scheduling of preventative maintenance can be optimized to eliminate either too little or too much maintenance. Further, the system automates a very paperintensive and time cumbersome process by permitting direct communication with the various information elements associated with an asset31. As a result, the flow of data is more effectively controlled, dispersed, routed, monitored, and acted upon. In practice, the number of people involved in the maintenance process can often be reduced while the speed of providing maintenance can be increased. Thus, potential downtime and related performance issues can be more timely addressed.