# Patent

## Title
Identification, categorization, and integration of unplanned maintenance, repair and overhaul work on mechanical equipment

## Abstract

An automated interactive method dynamically identifies an unplanned maintenance task during execution of a planned maintenance task on equipment. A user device displays a maintenance menu system for data entry and access and provides an input relating to unplanned maintenance task discovered on the equipment. The unplanned maintenance task is associated with the planned maintenance task at least with respect to a location. The automated interactive method sequentially processes unplanned maintenance task information based on the input from the user device. The automated interactive method establishes and stores an unplanned maintenance task data record including a selected geographical location, a selected item, a selected work category, a selected task type, a selected task description, and selected component data of the unplanned maintenance task.

## Background
PRIORITY
This application is a continuation of the U.S. Application Ser. No. 09/946,095, filed on Sep. 4, 2001 and matured to U.S. Pat. No. 7,440,906 on Oct. 21, 2008, the disclosure of which is incorporated herein by reference.


BACKGROUND
This application relates generally to managing maintenance of equipment. More particularly, this invention relates to identification, categorization, and integration of unplanned maintenance repair and overhaul (MRO) work in an MRO business organization.
A number of businesses focus their operations on the maintenance, repair or overhaul of complex equipment. Aircraft fleet and truck fleet maintenance are two commonly known businesses in this arena. In addition, other business that have to maintain expensive complex machinery and other capital equipment such as fully automated manufacturing plants also require the maintenance, repair and/or overhaul of their equipment to keep the business operations running profitably.
Historically, within MRO business organizations, resource planning has been performed as a product of resource availability within a very near term time window, usually within weeks. The specific scheduling activity of MRO tasks usually is the product of responding to emergencies and matters of necessities to keep a particular end item, or a piece of equipment, in service. The result is that maintenance schedules often serve as general guidelines with critical resources being poorly allocated. Those resources typically need to be continually swapped and reallocated in an ad hoc manner to meet the emergency maintenance needs. This informality often results in both excessive equipment down times and excessive cost of maintenance.
Scheduling systems have been developed to permit the performance of MRO tasks to a predefined schedule and support that schedule with the correct components, raw materials, information, skilled or certified personnel, tooling and facilities. The ability to reliably schedule MRO work is important to an MRO business and its customers. The predictability of schedule performance is one of the most difficult issues facing MRO management. Such predictability is the foundation of both financial and technical success for an MRO business.
In the MRO environment, and especially while performing maintenance on more technically complex end items, the discovery of unplanned work (also known as “above and beyond”, or “emergent” work) during the execution of the original maintenance plan is problematic. Such unplanned maintenance work increases the level of difficulty of the effort, makes the supporting of the original plan much less efficient, and can create chaos within the work schedule. Of all of the tasks which must be performed once an item of unplanned work is discovered, the actual identification and categorization of the work content for that unplanned item is one of the most crucial factors in successfully dealing with the unplanned work and the schedule.
Historically, the identification and categorization of such unplanned work has been manual in nature, open to great latitude in description (both as to accuracy and detail of the description), and time consuming for the mechanic or technician. Additionally, the time spent performing the essentially clerical task of identifying and categorizing the work is time lost from the execution of the already planned maintenance. This is a source of inefficiency and wasted resources.
In those industries subject to extensive government regulation, the degree of detail required in the description of such tasks compounds the problem further. For example, commercial and military aircraft MRO operations must be scheduled and logged in accordance with government requirements. Disruptions to the schedule must also be logged and accounted. Manual records must be maintained for subsequent verification by regulators. The processing of these manual records, the reaction of the full business to the content of those records (purchasing of components; assignments of personnel; etc.), and the degree of human error represented by those records has made them a serious roadblock to the improvement of the MRO businesses.
Further difficulty occurs when attempts are made to integrate newly identified and categorized work with a pre-existing maintenance plan. This difficulty arises in reference to the placement and sequencing of the discovered work within the pre-existing plan. This difficulty also arises in reference to the availability of the required components, information, tooling, and certified personnel to perform the tasks. A general rule of thumb is that over 50% of the tasks accomplished by an MRO activity were not part of the original workplan, and well over 60% of the time required to perform the tasks (and the cost associated with the maintenance business) are originally unplanned, meaning discovered during planned work execution.
Accordingly, there is a need for improved methods and apparatus for identification, categorization and integration of unplanned MRO work in a schedule of planned work.
BRIEF SUMMARY
By way of introduction only, the present invention provides an automated interactive method for dynamically identifying an unplanned maintenance task during execution of a planned maintenance task on equipment and creating a corresponding unplanned maintenance task data record associated with the planned maintenance task. The automated interactive method includes displaying on a user device a maintenance menu system for data entry and access, receiving from the user device a selected geographical location of unplanned maintenance work discovered on the equipment. The unplanned maintenance work includes a first unplanned maintenance task associated with the selected geographical location and a second unplanned maintenance task not associated with the selected geographical location. The automated interactive method also includes establishing, through a task pointer, a first path to the first unplanned maintenance task on the equipment, establishing, through a location pointer, a second path through the selected geographical location to both the planned maintenance task and the first unplanned maintenance task, and displaying on the user device the first unplanned maintenance task and suppressing display of the second unplanned maintenance task. The automated interactive method further includes receiving from the user device a selection specifying the first unplanned maintenance task at the selected geographical location of the equipment, receiving from the user device a selected work category to assign to the first unplanned maintenance task, receiving from the user device a selected task type to associate with the selected work category, determining a task description corresponding to the selected task type, acquiring component data for the first unplanned maintenance task; and establishing and storing in a memory a resultant unplanned maintenance task data record including the selected geographical location, the selected item, the selected work category, the selected task type, the task description, and the component data.
By way of introduction only, the present invention provides in one embodiment a method for managing maintenance of equipment. The method includes identifying a planned MRO task and a first set of components associated with the task and determining a set of probabilities associated with a second set of components and indicating that the second set of components will require maintenance during the planned MRO task. The method further includes developing a plan for maintenance of individual items in the second set of components and, upon discovering a need for maintenance of at least one item of the second set of components, accessing the plan and integrating it with a plan of planned MRO tasks for the equipment.
In another embodiment, the invention further provides a method for managing maintenance of equipment. The method includes discovering a component of the equipment requiring unplanned maintenance and identifying a location of the component. The method further includes identifying a category of work required for the unplanned maintenance, identifying a task description in the category of work to be performed, identifying a data code on the component, obtaining information from one or more databases associated with maintenance of said equipment, and scheduling the unplanned maintenance into a schedule of planned maintenance based on the information obtained from the one or more databases.
In yet another embodiment, the invention further provides a system for managing the maintenance of equipment by integrating planned maintenance with unplanned maintenance. The system includes a network user interface in communication with a network and at least one storage device in communication with the network, the storage device being configured to store data from a plurality of databases. These databases in one embodiment include a Planned Work Probable Findings database including data of probability that, during planned maintenance of a first component, a second component will be identified as requiring unplanned maintenance, a Geography Definition database including data defining physical zones within which a repair task may be performed on a piece of equipment, a Planned Work Geography Locator database including data associating a planned MRO task to a physical zone, and a Component Tracking database including data selected from one or more of part numbers, component serial numbers and tracking numbers, the Component Tracking database being linked to a configuration database; and a scheduler for scheduling maintenance for a plurality of maintenance time periods; wherein the network user interface is configured to provide access to data from one or more database to describe a MRO task for a component of the equipment discovered to require maintenance; and wherein said scheduler includes logic to integrate the maintenance of the second component into a maintenance plan for said maintenance in a selected time period.
In yet another embodiment, the invention further provides a method for managing maintenance of equipment. The method includes identifying a planned MRO task of the equipment and based on location of the planned MRO task, retrieving from a memory probable MRO tasks associated with the planned MRO task.
In yet another embodiment, the invention further provides a computer readable equipment maintenance database storage medium. The storage medium includes first data defining planned maintenance items for equipment and second data defining probable maintenance items for the equipment. The second data is associated with the first data by geographic data for the equipment.
In yet another embodiment, the invention further provides a method for forming an equipment maintenance database. The method includes identifying a planned MRO task for equipment and identifying one or more geographical areas of the equipment associated with completion of the planned MRO task. The method further includes determining unplanned MRO tasks associated with the one or more geographical areas and, in a database, storing first data related to the planned MRO task, storing second data related to the unplanned MRO tasks, and associating the first data and the second data by data related to the one or more geographical areas of the equipment.
The foregoing summary has been provided only by way of introduction. Nothing in this section should be taken as a limitation on the following claims, which define the scope of the invention.



BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a block diagram of a system for managing maintenance of equipment;
FIG. 2 is a flow diagram illustrating one embodiment of a method of operating the system of FIG. 1;
FIG. 3 illustrates one embodiment of a planned work probable findings database of FIG. 1; and
FIG. 4 illustrates a question and response session gathering data to permit integration of unplanned work with a planned work schedule.



DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawing, FIG. 1 is a block diagram of a system 100 for managing maintenance of equipment. As used herein, equipment refers to a machine or machinery that is formed of a defined arrangement of multiple components. A component means a component, a sub-component, an assembly, a system, or any other part of an item of equipment. A component may include, but need not include, one or more sub-components. An assembly may comprise a group of components that are integrated together. A material refers to raw material, a consumable, a component, a provision, or other equipment-related resources related to the performance of a maintenance activity. A maintenance activity or a maintenance task refers to at least one of maintenance, repair and overhaul of an item of equipment or a component of the item.
A component is not limited to mechanical elements and is broadly defined to include an electrical assembly, an electrical system, an electronic system, a computer controller, software, hydraulics, plumbing, and the like. Mechanical equipment includes heavy equipment and capital intensive equipment that is movable or fixed. Mobile mechanical equipment includes airplanes, buses, locomotives, ships, cranes, heavy trucks, earth moving equipment, and the like. Fixed mechanical equipment includes electrical power generators, industrial presses, manufacturing equipment or the like.
The system 100 forms a system for managing the maintenance of equipment by integrating planned maintenance of the equipment with unplanned maintenance for the equipment. In one exemplary embodiment described herein, the system 100 may be used in conjunction with a maintenance, repair and overhaul (MRO) system for performing MRO work on equipment. In another exemplary embodiment, the system 100 is used by a provider of MRO services for airplanes such as military and commercial airplanes. However, the system is not so limited and may be used in conjunction with any type of equipment or system.
The system 100 includes a computer network 102, a user interface 104, a server 106, a storage device 108 and a scheduler 110. The network 102 may be any suitable data communications network, such as a local area network, wireless network, etc. Many networking standards have been developed and may be adapted for application as shown in FIG. 1 and described herein.
The user interface 104 is in communication with the network 102 and provides access to data and applications located remotely on the network 102. In the illustrative embodiment, the user interface 104 is embodied as a personal computer. In other embodiments, different types of data entry and data communication devices may be used. For example, in one alternative embodiment shown in FIG. 1, a wearable data communication device 112 is in communication with the user interface 104 by means of a wireless network 114. The wearable communication device 112 forms a wireless data entry device in communication with other components of the network 102. The wearable communication device 112 permits an operator such as a technician or mechanic to access remote locations of equipment undergoing MRO work while remaining in data communication with the network 102 but without the inconvenience of trailing data cables. Other types of data entry devices are known and may be adapted for use in the system 100.
The server 106 provides a process workflow and messaging device for the system 100. The server 106 is in communication with the user interface 104, the storage device 108 and the scheduler 110. The server 106 may also provide data communication with other devices, such as other networks.
The storage device 108 is in communication with other components of the network 102. The storage device is configured to store data in a plurality of databases. These databases include a planned work probable findings database 116, a planned work geography located database 118, a work description library 120, a geography definition database 122, a standard repair library 124, a standard parts list 126, a component part and serial number database 128, configuration databases 130 and possibly other databases 132. The other databases 132 may store ancillary information such as data and applications for use by components such as the server 106 and the user interface 104 of the network. The content and creation of these databases along with their use for scheduling planned and unplanned MRO work will be described in more detail below.
MRO work is organized by task. Examples of aircraft MRO tasks are “overhaul engine number 1,” or “inspect brake pads on nose landing gear.” Many MRO tasks are planned and scheduled according to a regular preventative maintenance schedule or other planning basis. For each planned MRO task, an analysis is performed to determine what types of additional, unplanned MRO work may be found during routine maintenance within the same geographical area of the equipment. Relative probabilities are assigned to those possible work events and the planned work probable findings database 116 is established from that analysis. One example of data organized in a planned work probable findings database is shown in FIG. 3.
Defined categories of MRO work, such as mechanical, electrical, software, etc. are specified along with expected types of tasks relative to that category. For example, plumbing could be expected to have leaks of varying severity, including seepage, pooling, heavy volume, burst pipe, etc. As another example, structural failures could include task types such as corrosion, cracking, fastener loss and bending, etc. For each of these categories and tasks types, standard nomenclature is developed and category/task-type pairs are established. The resulting data is stored in the work description library database 120.
For each unplanned work category/task type pair identified in the work description library database 120, a standard method of repair is established and associated data is stored in the standard repair library database 124. This library, in one embodiment, includes task descriptions, basic required tool listings as well as any special processing notes, skills or certifications required for the task, including safety warnings. This database also includes both schedule span estimates and cost estimates of the effort required to accomplish the standard repair tasks.
For each entry in the standard repair library database 124, a generalized components list of the items forecast to be required to be perform a specified maintenance or repair task is established in the standard repair parts list library database 126. This database may be organized by part numbers or nomenclature or both. In case of a database organized according to nomenclature only, various analysis techniques related to the context of the semantics used to describe the components may be applied to determined proper part applications for the various configurations.
The equipment geography description database 122 stores data related to geographic zones or locations for all maintained areas of the end item of equipment. This may include detailed information about subareas, focused on defining where maintenance work has been located on the end item of equipment. For example, geography must be specified as “right-hand front fender—rear edge” or “left-hand forward wheel well—pump mount side.” Only those areas determined to be subject to frequent or expensive maintenance may be listed. Preferably, the geographic location descriptions are related to a user graphical interface allowing for rapid point-and-click data acquisition. That is, a user operating a pointer-type device in conjunction with a display device may find and identify a specific geographic location or zone quickly using a graphical user interface. In instances where industry regulatory entities have pre-established geographic areas or zones or sub-zones, such as the ATA zones specified by the Air Transport Association for commercial aircraft, utilization or cross references may made to those standards in the geographic description database 122. An example of the ATA zones is provided herein as an appendix.
The component part/serial number database 128 stores part numbers or component serial numbers or some other unique tracking number for components of the equipment. The configuration database 130 stores information about the configuration or interrelationship of the components and parts of the equipment. These databases may be accessed for additional information about equipment needing repair or replacement.
While the several databases shown in FIG. 1 and described herein are independent in this embodiment, other data storage embodiments may be used. The data associated with the respective databases may be combined or linked in one or more databases. Databases may be located together as shown or distributed about the network. Any suitable database management tool or applications may be used for managing and maintaining the databases.
The scheduler 110 schedules maintenance for a plurality of maintenance time periods for equipment as part of the operation of the MRO system. As noted above, some MRO work occurs according to a schedule, such as routine preventative maintenance or overhaul work. Some MRO work may be planned but unscheduled, such as repairs. The scheduler 110 tracks work that must be performed over time against a calendar and using information about availability of other resources.
The scheduler 110 is illustrated in FIG. 1 as a computer in communication with the network 102 with access to the storage device 108 including its databases, the server 106 and user interface 104. In other embodiments, the functionality provided by the scheduler 110 may be performed by other components of the system 100. For example, a processor associated with the server 106 may perform the functions provided by the scheduler 110.
The scheduler receives data inputs regarding equipment on which maintenance is to be performed, the maintenance to be performed on the equipment, and resources available to perform the maintenance, such as parts and personnel. The scheduler may also receive other information such as availability of the equipment and planned maintenance schedules for the equipment. Using this information and other required information, the scheduler 110 develops a maintenance plan for maintenance in a selected time period for specified equipment. As will be described in greater detail herein, the scheduler 110 further receives information about unplanned work identified, for example, by a technician during inspection or performance of other work. The scheduler 110 integrates performance of the unplanned maintenance work into the maintenance plan for the equipment.
It is to be noted that other embodiments of the system 100 may be substituted. The functionality provided by the system may be alternately provided by computation and data storage devices having any configuration which is suitable to the needs and purposes described herein. The configuration shown in FIG. 1 is exemplary only and is intended to clarify the function of the various elements of the system described therein.
FIG. 2 is a flow diagram illustrating one embodiment of a method for operating the system 100 of FIG. 1. The method illustrated in FIG. 2 permits identification, categorization and integration of unplanned MRO work in a schedule for completion of planned MRO work. The method begins at block 200.
At block 202, unplanned MRO work is discovered. This may occur at any point in the MRO work process. For example, the unplanned work may be discovered before the equipment is delivered for MRO processing. The MRO work may be discovered while planned MRO work is under way, for example, when the equipment has been opened up for access to a planned work area.
In accordance with one embodiment, for each item of unplanned work discovered, an MRO technician or mechanic utilizes a computer input device to define the location of the work on the equipment. Two techniques for location definition are envisioned, and others may be implemented as well. In one technique, the location of the unplanned work is specified using the most relevant planned work definition, as specified in the probable findings database 116 (FIG. 1), as will be described in greater detail below. Alternatively, the unplanned work can be specified through an assigned MRO geography definition. This definition may be obtained, for example, from the geography definition database 122 (FIG. 1). In the example involving aircraft MRO work, this information may be specified in the format of standard codes and locations for aircraft specified by the Air Transport Association, shown in the appendix hereto. For example, those standard codes may be specified as a default definition database. If other definitions are specified, for example by a specific airline which operates an aircraft, the preferred definitions may be substitute for the standard, default codes and locations.
Preferably, the location definition operation described by block 204 occurs when the technician clicks on an item on a menu. The menu may be presented to the technician by means of the user interface 104 or a device such as the wireless data communication device 112 in communication with the user interface 104. It is envisioned that the user interface will provide an easy to navigate menu system for data entry and access by a technician, mechanic or other operator. The menus are preferably dynamic pop up or pull down menus, with menu selections varying with the context of the menu. Only appropriate menu choices are provided to the user depending on his current context or location in the menu system or level of operation.
At block 206, the operator specifies the geography/work pairing for the unplanned work items. Preferably, this is accomplished using a point and click menu system associated with a user interface. The menu system may be used to access or specify the particular geographical location of the equipment. The menu system may further be used to select or identify a particular item of unplanned MRO work to be completed at the specified geographical location. This task description selection is preferably based on a pull down menu of relevant information only, and a click-to-verify method for input. That is, once the geographical location has been identified by the operator, only the possible work tasks in that geographical location are made available by the menu system. If the operator specifies an area of the assembly where only hydraulic systems are located, only hydraulic work tasks will be displayed by the menu system. Other tasks, such as electrical tasks and airframes repair tasks, will be suppressed.
At block 208, the operator identifies and verifies the work category for the items of unplanned work. Preferably, different tasks are specified in different categories of work. For example, in the airplane repair context, categorization may assign tasks to categories such as hydraulics, electrical, airframe repair, etc. Categorization can be important to allow allocation of proper and necessary resources for completion of the planned and unplanned work. Alternatively, the tasks could be categorized by geography, specifying physical regions of the equipment under repair for categories to which work tasks may be assigned.
At block 210, a task description for the unplanned work tasks is identified and verified. Again, this is preferably accomplished using a pull down menu of relevant information, along with a click-to-verify method for input. Based on the information provided by the technician, the system responds with a pull down menu whose entries are limited to only relevant or proper entries. Irrelevant or improper entries are suppressed.
At block 212, component data is acquired by the system. In one embodiment, this is done by reading a data code from the device. The data code may be machine readable, such as a bar code or magnetic stripe or may be a part number or serial number attached to the device. The data code is a unique identifier of the device. In another embodiment, this is done by posing tailored questions to the operator to obtain the required information. The questions may be posed using a video entry device associated with the user interface of the system or with the wearable communication device. Alternatively, an audio interface may be provided. The questions are tailored to the type of MRO task already identified by the technician. In one example, the following questions may be transmitted to the operator for data entry.

    
    
        Does the item to be maintained have a digital media (bar code/magnetic stripe, etc.) attached? If yes, input the information by scanning it now.
        If no such media identifier exists, input the serial number printed or stamped on the item, or input “no” if none exists.
        Should the item be removed for further work, yes/no.
        Additional tailored questions may be asked as required.
    
    


At this point, the answers to the tailored questions along with other data entered by the operator have provided the system with sufficient information to draw inferences as to the next steps required. Any appropriate or available application may be employed to perform necessary logical operations to process the input information. The system can accordingly initiate required transactions in support of those next steps.
The information provided by the operator and obtained from the storage device of the system allows the system to fully identify and describe the unplanned work task. At block 214, the system establishes an unplanned task data record, which may be located in a portion of memory for storing data related to the unplanned task. At block 216, the system determines a time span/cost estimate for the unplanned task. The time and cost estimates may be based on prior art data or experience performing similar unplanned work. At block 218, the system orders the necessary support for the task. Examples of required support include components for repair and replacement, information such as directions, and personnel.
At block 220, the unplanned work is sequenced into the planned work sequence to produce a revised work plan. This forms the preparation of an integrated schedule including the original work tasks and the newly discovered tasks. After producing the revised work plan, the method illustrated in FIG. 2 terminates at block 222. Additional or alternate actions may be taken in other embodiments.
It may happen that the system cannot develop the necessary described linkages. In that case, a transaction is produced by the system to a maintenance control area for further analysis or engineering assistance. In all cases, the unplanned work is fully identified, categorized and integrated to the total work plan prior to executing the repair task. This reduces or eliminates the uncertainty and variability formerly associated with unplanned MRO work.
FIG. 3 illustrates one embodiment of the planned work probable findings database. The database 116 is preferably contained on a storage medium such as a hard-disk drive, semiconductor memory or other electronic storage. The storage device or storage medium forms a computer readable equipment maintenance database storage medium. The database includes first data defining planned maintenance items for equipment and second data defining probable maintenance items for the equipment. The second data are associated with the first data by geographic data for the equipment.
In the embodiment illustrated in FIG. 3, the first data are organized as a series of planned MRO tasks 302, 304, 306. A task pointer 308 points to one of their designated tasks. Only three MRO tasks are shown in 302, 304, 306 FIG. 3 but the database 116 may contain any number of tasks. Associated with each planned MRO tasks 302, 304, 306 are one or more probable maintenance items. Thus, associated with a first plan MRO task 302 are a first probable MRO task 310, a second probable MRO task 312, and a third probable MRO task 314. Any number of probable MRO tasks may be associated with each planned MRO task. FIG. 3 is exemplary only.
Linking the planned MRO tasks and the probable maintenance items is location data. The location data defines the physical or geographical location of the equipment where the components associated with the planned maintenance and probable maintenance may be found. The location for respective probable maintenance items associated with a common planned MRO task may vary. A location pointer 316 points to the currently accessed location in the database. Thus, this database may be considered a two-sided database.
Two-way operation of the database 116 may occur as follows. The database may be accessed using any suitable database management system or other user interface. Preferably, in the embodiment of FIG. 1, a pull down menu system is used to display data from the database 116. By pointing and clicking with a pointer-type device, for example, the task pointer 308 or the location pointer 316 may be moved to select different database entries. By specifying a planned MRO task as indicated by the task pointer 308, all probable maintenance items associated with that planned MRO task can be located. Similarly, by specifying a geographic location using the location pointer 316 into the database 116, all planned maintenance such as planned MRO task 302 and probable or unplanned maintenance items such as tasks 310, 312, 314 associated with that location can be identified.
It should be noted that there may be several different location entries which may be associated with a single planned MRO task 302, 304, 306. For example, in the airplane context, if the planned MRO task 302 is described as “inspect air conditioning air ducts,” such ducts run the length of the plane, in a plurality of locations. Each separate location may have a separate probable MRO task 312, 312, 314 associated therewith.
The planned work geography locator database 116 can be formed in any suitable method. In one embodiment, this database is formed by identifying a planned MRO task for particular equipment and identifying one or more geographical areas of the equipment associated with completion of the planned MRO task. Subsequently, unplanned MRO tasks are identified which are associated with the one or more geographical areas. For example, a planned MRO task may be identified as “inspect left wing hydraulic lines.” The geographical areas for the airplane associated with this MRO task may be identified as the left wing and individual components and spaces thereof. An example of unplanned MRO tasks associated with the one or more geographical areas is “left wing airframe damage” or “worn electrical cables in left wing.”
The method for forming the equipment maintenance database further includes storing in a database first data related to the planned MRO task. This data may define, for example, an element or component requiring maintenance and the particular maintenance to be performed. The method further includes storing second data in the database, the second data related to the unplanned MRO tasks which have been identified for the geographical areas associated with the planned MRO task. The method still further includes associating the first data and second data by geographic data related to one or more geographical areas of the equipment. In one example, the geographical data may be data related to the codes established by the Air Transport Association industry organization to define an standard reference characteristic the geographical locations of an airplane. Examples of these codes are included herewith as an Appendix.
FIG. 4 illustrates a tailored question and response session between the system of FIG. 1 and an operator to gather data to permit integration of unplanned work tasks with a planned work schedule. At block 402, the operator is prompted to identify the item for maintenance. At block 404, the data entered by the operator is received. At block 406, the operator is asked if the specified item should be removed for further work. A response input is received at block 408. If a yes response is received, block 410, the operator is asked if a special fixture is required at block 412. A yes or no response is received at block 414.
At block 416, the operator is prompted to enter a required time for completion of the unplanned MRO task. A response is received at block 418. In addition, in one embodiment, external data is also received related to timing and duration of maintenance work. In one example, some airlines specify a very short turnaround time, meaning the duration from arrival of an airplane at an airport gate until subsequent departure of the plane on a next flight from the gate. Some airlines specify a turnaround time of 20 minutes. Other airlines specify a turnaround time of, for example, one hour. This information may be used, in conjunction with the data entered at block 418 to schedule the unplanned maintenance. Thus, if the data entered requires less than one hour for completion, and the turnaround time received at block 420 is an hour or more, the system may conclude that this unplanned work item may be completed during a turnaround process, assuming personnel and the equipment required for the task are available.
At block 422 the operator is prompted for a need for evaluation of the completed work. A response is received at block 424. At block 426, the operator is asked if an engineer is required for completion of the task. A response is received at block 428. At block 430, the operator is asked if quality assurance personnel are required for completion of the work item. A response is received at block 432. At block 434, the operator is asked if a lead technician or mechanic is required for completion of the task. A response is received at block 436.
Other questions may be asked of the operator based on the location and nature of the unplanned work to be performed and based on other information provided in the responses to the questions. The questions may be viewed as a tree, where the branch taken in the tree by the system is dependent upon the input received from the operator. Any number of questions may be generated depending upon the responses provided by the operator. Preferably, the number of questions is limited to the range of six to ten questions which are fairly general in nature for ready response by the operator.
From the foregoing, it can be seen that the present invention provides method and apparatus for identification, categorization and integration of unplanned MRO work in an MRO work schedule. A technician identifies location of the unplanned work and answers tailored questions posed by the system to obtain additional information about the nature of the work. Using this information, the system identifies and describes the unplanned work tasks and modifies the schedule for planned maintenance work to include the identified unplanned work. In this manner, the required components, information, tooling and personnel to perform the tasks, both unplanned and planned tasks, may be scheduled for efficient utilization and completion of the work schedule.
While a particular embodiment of the present invention has been shown and described, modifications may be made. It is therefore intended in the appended claims to cover such changes and modifications which follow in the true spirit and scope of the invention.







APPENDIX







ATA CODES








05 MTC CHECKS
22 AUTO FLIGHT


10 Time Limit
10 Auto Pilot & Flight Director *


20 Scheduled Checks
Pitch/Roll/Annunciation


21 Trans Check
20 Speed-Attitude Correction


23 #1 Layover
YAW Damp


25 #2 & ER Layover Checks
Speed/Mach or Pitch Trim


50 Unscheduled Checks
Stability Augmentation










Hard Landing
30 AutoThrottle



Turbulent Air
Thrust Management



Lightning Strike
40 System Monitor



Over-weight Landing
MCDP



Bird Strike
DLC/Auto Ground Spoilers










Pre-Ferry Inspection
(L 1011 only)








21 AIR CONDITIONING
70 Aerodynamic Load Alleviating


10 Compression
Active Control System


20 Distribution
23 COMMUNICATIONS










Conditioned Air Ducts
10 VHF



Lav/Galley Vent System
20 VHF and UHF










Recirculation Fan System
SELCAL










Gasper
30 Passenger Address










Equipment Cooling
and Entertainment








30 Pressurization
Audio and Video










Control & Indication
Tape Recorders










Relief Valves
35 Sky Radio








40 Heating
40 Interphone










Cargo Heat
Cabin and Service










Floor/Foot/Shoulder Heat
50 Audio Integrating










Hot Air Manifold Heat
Flight Interphone








50 Cooling
Cockpit Microphones/Headsets










Air Cycle Machine
and Loudspeakers










ACM Control & Ind.(ACM Only)
60 Static Discharge



ACM Valves
70 Voice Recorder



ACM Controller
80 ACARS








60 Temp. Control
90 Air to Ground Telephones










Zone Temp. Controller
(Airfone, Satcom)










Zone Trim System
91 ARINC 629



Compartment & Zone Ind.
93 Overhead Panel ARINC








70 Humidity Regulation
System (OPAS)








73 Ozone Control
94 Onboard Local Area









Network (OLAN)








24 ELECTRICAL POWER
27 FLIGHT CONTROLS










09Electrical Load Management
02 Primary Flight Controls










System (ELMS)
03 High Lift Control System








10 Generator Drive CSD and IDG
10 Ailerons








20 AC Generation
Aileron Trim










Generators
Control Wheel



Generator Control Panels
Aileron Pos. Indication










Indication (AC)
20 Rudder








30 DC Generation
Rudder Trim










Transformation Rectifiers
Rudder Pedals



Battery and Battery Charging
Rudder Indication










Indication (AC)
30 Elevator








35 Flight Control D/C Power
Elevator Feel


40 External Power
Control Column










Bus Power Control Unit
Elevator Indication








50 Electrical Distribution
40 Horizontal Stabilizer










Ground Service
Stabilizer Trim



Utility Buses
Stabilizer Pos. Indication










Generator/Bus Tie Breakers
50 Flaps








25 EQUIPMENT & FURNISHINGS
Asymmetry Control


10 Flight Compartment
Load Relief


20 Passenger Compartment
Flap Pos. Indication








25 Cabin Maintenance Visit
60 Spoilers/Speedbrakes








30 Buffet and Galley
Spoiler Pos. Indication










Service Areas
70 Gust Lock



Ovens/Chillers/Dispensers
80 Leading Edge Lift Augmenting










Carts
Leading Edge Slats/Flaps or Slots



Elevators or Lifts
Auto Slat Extension System








40 Lavatories
Asymmetry Control


50 Cargo and Accessory
Slat or Flap Pos. Indication










Compartments
28 FUEL










Cargo Loading Systems
10 Storage








60 Emergency Equipment
20 Distribution








88 Cabin Cleaning Operation
Plumbing


26 FIRE PROTECTION
Pumps


10 Detection
Valves










Fire/Overheat or Smoke
30 Dump








20 Extinguishing
40 Indicating










Fixed or Portable Extinguishers
Quantity








30 Explosion Suppression
Temperature










Fuel System Protection
Pressure








29 HYDRAULIC POWER
32 LANDING GEAR


10 Main
10 Main Gear and Doors


20 Auxiliary
20 Nose Gear and Doors










Emergency or Standby
30 Extension and Retraction










RAT
Actuators and Control System








30 Indication
Latches and Locks










Quantity
Truck Positioning (Tilt)










Temperature
40 Wheels and Brakes










Pressure
Wheel Assemblies








30 ICE & RAIN PROTECTION
Parking Brakes


10 Airfoil
42 Anti-skid System, Autobrakes


20 Air Intakes
43 Tire Foreign Object Damage










Cowl Anti-icing
(Puncture Damage)








30 Pitot and Static
50 Steering


40 Windshields and Windows
60 Position and Warning








50 Antennas and Radomes
Landing Gear/Supplementary Gear


60 Propellers/Rotors
and Gear Door Warning and


70 Water Lines
Indication System










Supply and Drain
Proximity Switch Electronic Unit








80 Detection
70 Supplementary Gear










Ice Detector and Annunciation
Tail Skid








31 INSTRUMENTS
33 LIGHTS


09 System Card Files
10 Flight Compartment


10 Panels
20 Passenger Compartment








20 Independent Instruments
Galley and Lavatories










Clocks
Sign Illumination








30 Recorders
30 Cargo and Service Compartments










Flight Recorders/FDAU
40 Exterior Lighting








35 Aircraft Conditioning
50 Emergency Lighting










Monitoring System (ACMS)
Flashlights







40 Computers









Engine Indicating Crew









Alerting System (EICAS)









Multi-Acquisition Processor (MAP)







41 Airplane Information









Management System (AIMS)







50 Central Warning









Aural Warning



Takeoff/Landing Warning








34 NAVIGATION
38 WATER/WASTE


10 Flight Environment Data
10 Portable










Pilot and Static Systems
Storage



Altitude/Altitude Alert
Distribution



A/S and Over-speed Warning
Quantity Ind.










V/S
30 Waste Disposal










Air Data Computers
Wash Basins



Stall Warning
Water Closets



Air Temperature
Flushing Systems








20 Attitude and Heading
40 Air Supply










Electronic Flight Instrument Systems
Tank Pressurization










Attitude Indicator Systems
45 CENTRAL FAULT DISPLAY










Magnetic Heading Systems
SYSTEM



Directional and Vertical Gyros











Turn and Bank
49 AIRBORNE AUXILIARY POWER



Standby Horizon
10 Power Plant










Air Data Inertial Reference System
Mounts










(ADIRS)
Fireseals








30 Landing and Taxi Aids
Electrical Harness










ILS and Marker Beacon Systems
Intake



Radio Altimeter System
Drains










Monitor/Comparators
20 Engine








40 Independent Position Determining
Accessory Gearbox










INS or IRU
30 Engine Fuel and Control










Weather Radar
Electronic Controller










Ground Proximity Warning System
40 Ignition and Starting








“Collision Avoidance (TCAS, Windshear)”
Starter








50 Dependent Position Determining
50 Air










ADF - ATC - VOR
Accessory Cooling



OMEGA - DME - GPS
Pneumatic Supply








60 Flight Management
60 Engine Controls








35 OXYGEN
Emergency Shutdown








10 Crew
70 Engine Indicating








20 Passenger
Speed and Temperature








30 Portable
80 Exhaust


36 PNEUMATIC
90 Oil








10 Distribution
Storage










Control System
Distribution



Ducts
Indication







20 Indication









Temp and Pressure (duct)








52 DOORS
54 NACELLES/PYLONS


10 Passenger/Crew
10 Main Frame










Steps
Pylon/Strut



Actuation
Keels








20 Emergency Exits
30 Plates/Skins










Emergency Actuation System
Access Covers








30 Cargo
40 Attach Fittings










Doors and Actuation System
Thrust Reverser








40 Service
Attach Fittings








50 Fixed Interior
50 Fillets/Fairings










Flight Compartment
Pylon to Wing/Eng Fairing










Lavatory
55 STABILIZER








60 Entrance Stairs
10 Horizontal










Actuation
Plates/Skin










Control and Indication
20 Elevator








70 Door Warning
Plates/Skin










Passenger/Service Accessory
Balance Devices










Compt. And Stairs Ind.
Tabs










Code Landing Gear Doors
30 Vertical










Under Chp. 32
Plates/Skin








53 FUSELAGE
40 Rudder








10 Main Frame
Plates/Skin










Bulkheads and Keels
Balance Devices








20 Auxiliary Structure
Tabs










Floors
50 Attach Fittings










Fixed Partitions
Horizontal and Vertical Stab/Elev








30 Plates and Skins
and Rudder Component










Doublers
56 WINDOWS








40 Attach Fittings
10 Flight Compartments










Door/Gear/Wing and Engine
20 Cabin










Pylon Attach Fittings
30 Door










Seat Tracks
40 Inspection and Observation







50 Aerodynamic Fairings









Fillets



Radome/Tail Cone








57 WINGS
72 ENGINE


10 Main Frame
10 Reduction Gear and Shaft










Primary Structure
(Turbo-prop)








20 Auxiliary Structure
20 Air Inlet Section










Leading/Trailing Edge
Fan Case



Wing Tips
Guide Vanes (Fixed)










Fairing/Fillets
30 Compressor Section








30 Plates/Skin
Compressor - Front/Intermediate/Rear


40 Attach Fittings
Diffuser Case










Pylon/Control Surface and Landing
39 Compressor Stall










Gear Attach Fittings
40 Combustion Section








50 Flight Surfaces
Burner Cans










Ailerons and Tabs
Combustion Chamber and Ducts



Spoilers
Case










Flaps
50 Turbine Section










Leading Edge Lift Devices
Turbine Nozzles/Rotors/Cases








71 POWERPLANT
Exhaust Section








03 Foreign Object Damage (FOD)
60 Accessory Drive Section








10 Cowling
Engine Mounted Gearbox










Inlet
70 By Pass Section










Accessory
Fan Exist Case



Core
Air Bleed Manifolds








20 Mounts
73 ENGINE FUEL & CONTROL










Engine to Pylon
10 Distribution








30 Fire Seals
Pumps










Power Plant Mounted
Filters








40 Attach Fittings
Nozzles










Power Plant Accessory Attach
Valves








50 Electrical Harness
Tubes










Wiring Disconnected and Removed
20 Controlling










with Engine
Fuel Control








60 Variable Air Intakes
Electronic Engine Control (FADEC)


70 Engine Drains
Thrust Lever Resolvers


98 Max Power Takeoff
EEC Alternator










MAX Power T/O (L1011-1 and
Propulsion Discrete Interface Unit










MD 88/90)
30 Indication










NORM Power T/O (B 767 Domestic
Fuel Flow










W/PW 4060)
Fuel Temp










ARTS Fired (MD88)
Engine Pump Fuel Press









Filter Bypass








74 IGNITION
77 ENGINE INDICATING


10 Elect Power Supply Exciter
10 Power








20 Distribution
EPR










Ignition Lead
Tachometer (N1/N2/N3)



Igniter Plug
Engine Synch








30 Switching
20 Temperature










Ignition Control Circuit
EGT/TGT








75 AIR
30 Analyzers








10 Engine Anti-icing
Airborne Vibration Monitor










Cowl Anti-icing Code Under
Electronic Engine Control Monitor










Chp. 30
78 EXHAUST








20 Accessory Cooling
10 Collector/Nozzle










Ducts and Tubing
20 Noise Suppressor










Generator Cooling
(exhaust gas noise only)










Bearing Cooling
30 Thrust Reverser










Ignition Cooling
Fan/Turbine Reverser



Active Clearance Control
Control System










(Case cooling)
Indication System










Turbine Cooling
79 OIL








30 Compressor Control
10 Storage










Variable Stator Vanes
Engine Tank



Bleed Valves
20 Distribution










Actuator (VSV)
Engine Lubricating System








40 Indication
30 Indication










Engine Air Control System
Quantity



Indication
Temperature








76 ENGINE CONTROLS
Pressure










(Use 2230 for Autothrottles)
Filter Bypass








10 Power Controls
80 STARTING










Levels
10 Cranking










Cables
Starter System










Bell Cranks
99 MISCELLANEOUS










Tension Regulators
Board Forms







20 Emergency Shutdown


“Engine”“T”“Handle”









Shutdown Circuits

## Claims

1. An automated interactive method for dynamically identifying an unplanned maintenance task during execution of a planned maintenance task on equipment and creating a corresponding unplanned maintenance task data record associated with the planned maintenance task, the method comprising:
displaying on a user device a maintenance menu system for data entry and access;
receiving from the user device a selected geographical location of unplanned maintenance work discovered on the equipment, the unplanned maintenance work comprising a first unplanned maintenance task associated with the selected geographical location and a second unplanned maintenance task not associated with the selected geographical location;
establishing, through a task pointer, a first path to the first unplanned maintenance task on the equipment;
establishing, through a location pointer, a second path through the selected geographical location to both the planned maintenance task and the first unplanned maintenance task;
displaying on the user device the first unplanned maintenance task and suppressing display of the second unplanned maintenance task;
receiving from the user device a selection specifying the first unplanned maintenance task at the selected geographical location of the equipment;
receiving from the user device a selected work category to assign to the first unplanned maintenance task;
receiving from the user device a selected task type to associate with the selected work category;
determining a task description corresponding to the selected task type;
acquiring component data for the first unplanned maintenance task; and
establishing and storing in a memory a resultant unplanned maintenance task data record comprising the selected geographical location, the selected work category, the selected task type, the task description, and the component data.

2. The method of claim 1, wherein the selected work category specifies a maintenance field operable to distinguish between a mechanical field, an electrical field and a software field.

3. The method of claim 1, wherein the selected work category specifies a physical region of the equipment.

4. The method of claim 1, further comprising:
displaying on the user device relevant entries for receiving the task description according to the selected task type; and
suppressing a display of irrelevant entries with respect to the selected task type.

5. The method of claim 1, wherein acquiring component data comprises:
reading a machine readable unique data code from the equipment.

6. The method of claim 1, wherein acquiring component data comprises:
posing on the user device a tailored question to the selected task type.

7. The method of claim 1, further comprising:
preparing an integrated schedule including the planned maintenance task and the first unplanned maintenance task by sequencing the first unplanned maintenance task into a planned work sequence; and
generating a work plan incorporating the integrated schedule.

8. An automated interactive system for dynamically identifying an unplanned maintenance task during execution of a planned maintenance task on equipment and creating a corresponding unplanned maintenance task data record associated with the planned maintenance task, the system comprising:
a user interface in communication with a wearable user device operable to display a maintenance menu system for data entry and access, the user interface operable to:
receive from the wearable user device a selected geographical location of unplanned maintenance work discovered on equipment wherein the unplanned maintenance work comprising a first unplanned maintenance task associated with the selected geographical location and a second unplanned maintenance task not associated with the selected geographical location;
receive from the wearable user device a selection specifying the first unplanned maintenance task at the selected geographical location of the equipment;
receive from the wearable user device a selected work category to assign to the first unplanned maintenance task;
receive from the wearable user device a selected task type to associate with the selected work category; and
acquire component data for the first unplanned maintenance task;

a storage device configured to store maintenance data in a plurality of databases comprising:
a planned work probable findings database configured to establish, through a task pointer, a first path to the first unplanned maintenance task on the equipment;
a planned work geography located database configured to establish through a location pointer, a second path through the selected geographical location to the planned maintenance task;
a geography definition database configured to establish through the location pointer, the second path through the selected geographical location to the first unplanned maintenance task;
a work description library database configured to identify the selected work category and the selected task type; and
a standard repair library database configured to store a standard method of repair and associated data and to identify a task description corresponding to the selected task type; and

a maintenance server in communication with the user interface and the storage device and operable to establish a resultant unplanned maintenance task data record comprising the selected geographical location, the selected work category, the selected task type, the task description, and the component data.

9. The system of claim 8, further comprising:
a scheduler in communication with the maintenance server and operable to generate a work plan based on the planned maintenance task.

10. The system of claim 9, wherein the scheduler is further operable to prepare an integrated schedule including the planned maintenance task and the first unplanned maintenance task by sequencing the first unplanned maintenance task into a planned work sequence and to generate a revised work plan incorporating the integrated schedule.

11. The system of claim 8, wherein the maintenance server is operable to determine whether the resultant unplanned maintenance task data record can or cannot be developed based on linkages among the selected geographical location, the selected work category, the selected task type, the task description, and the component data.

12. The system of claim 11, wherein upon determination that the resultant unplanned maintenance task data record cannot be developed, the maintenance server is further operable to produce a transaction to a maintenance control area for further analysis or engineering assistance.

13. The system of claim 8, wherein the maintenance server is operable to, through the user interface, pose on the wearable user device an initial tailored question corresponding to the selected type, and present an additional tailored question chosen based on a response received by the wearable user device to the initial tailored question.

14. The system of claim 13, wherein the user interface is operable to present the tailored question to be viewed as a tree structure where a branch taken in the tree structure is dependent upon the response received from the wearable user device.

15. An automated interactive method for providing relevant maintenance information to a technician assigned to maintain equipment, the method comprising:
entering through a user interface unplanned maintenance work discovered while planned maintenance work is under way;
defining in a database contained on a storage medium a geographic location of the unplanned maintenance work by:
establishing in the database, through a task pointer, a first path to the unplanned maintenance work on the equipment;
establishing in the database, through a location pointer, a second path through the selected geographical location to both the planned maintenance work and the unplanned maintenance work;

selecting with a server comprising a processor and in communication with the user interface and the database a task paired with the geographic location of the unplanned maintenance work wherein once the geographic location is defined, a display of another task paired with a different geographic location is suppressed;
selecting with the server a work category of the selected task that shares resource allocated for the planned maintenance work;
selecting with the server a type of the selected task associated with the selected work category;
identifying with the server a task description corresponding to the selected type;
entering through the user interface component data for the unplanned maintenance work; and
establishing with a scheduler comprising a computer and in communication with the server a resultant unplanned maintenance work data record comprising the selected geographical location, the selected work category, the selected task type, the task description, and the component data.

16. The method of claim 15, further comprising:
prompting to enter a required time for completion of the discovered unplanned maintenance work.

17. The method of claim 15, further comprising:
prompting to enter a need for evaluation of the unplanned maintenance work upon completion.

18. The method of claim 15, further comprising:
prompting to enter a need for additional technicians or a need for a special technician comprising quality assurance personnel, a lead technician, or a lead mechanic for completion of the unplanned maintenance work.

19. The method of claim 15, further comprising:
displaying information corresponding to the selected type as a tree structure where a branch taken in the tree structure is dependent upon data entered from a technician.

20. The method of claim 15, further comprising:
determining that a resultant unplanned maintenance task data record cannot be developed based on linkages among the geographical location, the selected task, the selected work category, the selected task type, the task description, and the component data; and
generating and sending a transaction to a maintenance control area for further analysis or engineering assistance of the unplanned maintenance work.