Computer software for maintenance resource management6385621Abstract The invention is an integration software program that enables a user to use the logic and data accessible in a job standards development program to develop a job plan which is then transferred to a job planning software program where it is finalized and used to produce work orders. Integrating these two programs results in producing job plans rapidly and assures optimum utilization of labor, materials and tools. Claims I claim: Description TECHNICAL FIELD
TABLE 1
Name Size Remarks
JOBPLAN
JPNUM 10 Unique identifier for Job Plan
DESCRIPTION 200 Job Plan description
JPDURATION 8 Job duration in hours:min
LABORCODE 8 Lead Craft
JP2 4 Support Craft #1 size
JP3 4 Support Craft #2 size
JP4 4 Support Craft #3 size
JP5 4 Job Crew Size
JP6 20 Craft #1
JP7 20 Craft #2
JP8 20 Craft #3
JOB
OPERATION
JPNUM 10 Job Plan number
JPOPERATION 4 Job Plan Operation number
DESCRIPTION 200 Job Plan description
OPDURATION 8 Operation duration in
hours:min
JO1 4 Operation reference # in
AutoMOST
JO2 8 Useful block of time in
hours:mins
JO3 8 Daily Prep in hours:mins
JO4 8 Applied Schedule Factor
For ease in illustration, the invention will be described in relation to an example where no job plan operations are found. In such a case, the user will use the job standards program to create a job plan, thereby utilizing standards to build the job plan. The job standards program is accessed using the button as described previously. The job standards program will automatically generate an operation number and initiate a series of questions, which will generate each operation description with the associated time, labor, tools and materials. (Various questions are illustrated in FIGS. 6-18) For example, the questions can be whether the job requires a site inspection, what is the name of the equipment being worked on, what qualifier terms can apply (i.e., "pump", qualifier, "first sump") what is the action required, ("repair/replace") what specific part is involved ("impeller"), what is the frequency, is there job preparation time, is there another action required, is a test required, do you wish to change the lead craft designation? Of course, other questions are possible such as identifying special tools required, safety steps required, such as equipment lock out which may impact setup time, etc. Typically, a database for a facility will have the specific equipment predefined so that drop down lists are available. Once a piece of equipment is selected, the question can be whether you wish to select an operation/suboperation for that equipment that was previously developed. That is, the operation for replacing the impeller could have been developed before, and if so, could be selected also from a drop down list, to utilize the existing standard specification. The job crew size, manhours/duration, etc., are calculated automatically after the job operation is defined. At that point, the user can override the specified parameters and request an updated calculation to see how the changes affect the job plan. Once the operations/suboperations standards are created, including the parts needed, duration, craft, etc., these are available for use in creating new operations and new job plans. For example, an operation can involve disconnecting the piping to the first sump pump. This preliminary operation is stored and can be called up for use in many different repair operations. The Job Planning Software Program After each operation is identified and completed in the job standards program, the user is asked if the planning is complete. When the user answers yes, the details from the job standards program can be used to fill in the corresponding fields in the job planning screen. (See FIG. 5) Alternatively, the details are transferred as a complete job plan. Thus, a job plan is created using the methods based job standards program and the details loaded into the job planning software, the user obtaining a completed job plan with the job standards program generated information. A work order is then generated. At this point, the user can apply various adjustments, for example, to change the estimated job duration to allow for actual conditions such as a schedule factor to compensate for job site conditions which would delay completion of the work. For example, based on past performance over a defined period, such as over the past 4 to 14 weeks, an average of the difference between actual hours and estimated hours is taken and applied. For example, if actual work averages 10% more time than estimated, the prior over a six week period, this can be applied to the work order. This adjustment can also take into consideration differences in performance by craft, by type of equipment, etc. depending on the to preferences of the user. Generally, after the work is completed, the work order is returned and the actual time, materials and tools used are added to the database which allows for determination of the schedule factor, as well as provide a measure of overall performance. This schedule factor is calculated automatically and the user can be asked whether to apply the schedule factor to the duration hours and to the labor man-hours, by activating a work order update button on the job planning display or work order operations screen. Once activated, the work order operation and labor tables in the job planning program will be updated. Travel time is another adjustment which may be made on the work order operations screen. This requires that the location field on the work order be filled in so that the program can reference a table containing travel times in the facility, for example, it may take 15 minutes to travel from a workshop to the first sump pump. Daily preparation is another optional adjustment. This is the preparation time to start a job each day, such as time to collect tools and receive instructions from the foreman. Various examples showing preparation of job plans and work orders according to the present invention follow. Job Preparation Example 1 The user accesses a job planning screen in the job planning software, to prepare a job plan for replacing a broken shear pin. The user enters a job planning number and clicks onto the button to switch to the job standards program. The user then defines the first operation as follows:
Description: REPLACE BROKEN SHEAR PIN
Daily
Duration Prep
10 REPLACE BROKEN SHEAR PIN 0.81 0.00
IN WICKET GATE
1. Remove keeper plate
2. Setup hydraulic jack
3. Install jacking rod
4. Jack out shear pin
5. Hand ream shear pin hole
6. Install shear pin
7. Install keeper plate
8. Replace detector piping
20 REPLACE SHEAR PIN 1.62 0.11
1. Remove keeper plate
2. Setup hydraulic jack
3. Install jacking rod
4. Jack out shear pin
5. Hand ream shear pin hole
6. Install shear pin
7. Install keeper plate
CALCULATIONS Formula multi-activity analysis (MAA)Clock Time+(Sum of MAA Basic PrepTime/Crew Size) Note: Dividing the job prep time by the crew size is simply a man-hour to duration conversion. For Op 10 0.81 hrs+(0.00 hrs)/2 man crew=0.81 hrs Note: The MAA for replacing a broken shear pin would not be a task performed by itself so there would not be any job prep elements assigned to the analysis. For Op 20 1.04 hrs+(0.73 hrs+0.12 hrs+0.52 hrs)/2 man crew=1.62 hrs Note: The shear pins in the wicket gates on either side of the gate with the broken pin are replaced as a rule of caution. The time to replace one shear pin is 0.52 hours. Therefore, the duration for the site work to replace the other two pins is 2 pins.times.0.52 hours/pin=1.04 hours. The logic during job plan development asks for the frequency to be applied. After this information is developed, the user then can return to the job planning screen where either the fields are filled in from this data or saved as a complete job plan in the job planning program. The user then prepares to produce a work order as follows. WORK ORDER CALCULATION DEFINITIONS A. Duration after Schedule Factor--The operation duration time multiplied by the schedule factor. Operation duration time*schedule factor B. Daily Prep after Schedule Factor--The daily prep duration time multiplied by the schedule factor. Daily prep duration time*schedule factor C. Number of Days The number of days are required to properly apply the daily prep at the operation level and the total travel time for the job. This requires two separate calculations as shown below. C1. For Applying Daily Prep The duration of the operation divided by the available hours in a day. The available hours in a day are adjusted to omit the round trip travel and the daily prep. Sum of the operation duration times/(8.0-(2*one-way travel time)-B) C2. For Applying Total Travel Time The total duration of the job plan (sum of all operations) divided by the available hours in a day. The available hours in a day are adjusted to omit the round trip travel and the sum of the daily preps for each operation. Sum of the operation duration times/(8.0-(2*one-way travel time)-the sum of B for all operations) D. New Duration The new duration is the operation duration time after application of the schedule factor plus the daily prep after application of the schedule factor multiplied by the number of days. A+(B*C1) E. Travel Time The number of days multiplied by the round trip travel time. C2*(2*travel time) Note: The one-way travel time in C & E above is multiplied by 2 to account for a round trip travel time. EXAMPLE WORK ORDER
Description: REPLACE BROKEN SHEAR PIN
Assume: Schedule Factor = 2.0 One-way travel = 0.25 hours
Daily
Duration
Prep
10 REPLACE BROKEN SHEAR PIN 1.62
0.00
IN WICKET GATE
1. Remove keeper plate
2. Setup hydraulic jack
3. Install jacking rod
4. Jack out shear pin
5. Hand ream shear pin hole
6. Install shear pin
7. Install keeper plate
8. Replace detector piping
20 REPLACE SHEAR PIN 3.46
0.22
1. Remove keeper plate
2. Setup hydraulic jack
3. Install jacking rod
4. Jack out shear pin
5. Hand ream shear pin hole
6. Install shear pin
7. Install keeper plate
999 TRAVEL 0.50
Total 5.58 hrs
LABOR DISTRIBUTION
OP CRAFT CODE QTY HOURS
MANHOURS
10 MECHJP 2 1.62
3.24
20 MECHJP 2 3.46
6.92
999 MECHJP 2 0.50
1.00
TOTALS 5.58
11.16
WORK ORDER CALCULATIONS
Step Op Description Calculation
1. 10 Duration after Schedule Factor 0.81
hrs * 2.0 = 1.62 hrs
Daily Prep after Schedule Factor
0.00 hrs * 2.0 = 0.00 hrs
Total
1.62 hrs
2. 20 Duration after Schedule Factor 1.62
hrs * 2.0 = 3.24 hrs
Daily Prep after Schedule Factor
0.11 hrs * 2.0 = 0.22 hrs
Total
3.46 hrs
3. For application of job prep
10 Number of days 1.62 hrs/8.0 hrs - (2 *
0.25 hrs) - 0.00 hrs
=
1.62 hrs/7.5 hrs
= 0.22
= 1.0 day
20 Number of days 3.46 hrs/8.0 hrs - (2 *
0.25 hrs) - 0.22 hrs
=
3.46 hrs/7.28 hrs
= 0.48
= 1.0 day
For application of total travel time
(1.62 hrs + 3.46 hrs)/(8.0 hrs - (2
* 0.25 hrs) - (0.00 + 0.22) hrs
=
5.08 hrs/7.28 hrs
= 0.70
= 1.0 day
4. 10 New Duration 1.62 hrs + (1.0 day *
0.00 hrs) = 1.62 hrs
20 New Duration 3.24 hrs + (1.0 day *
0.22 hrs) = 3.46 hrs
5. 999 Travel Time 1.0 day * (2.0 *
0.25 hrs) = 0.50 hrs
Note: The bold numbers are the ones used in the work order on the previous
page.
Job Preparation Example 2 The user accesses a job planning screen in the job planning software, to prepare a job plan for disassembly of a servo motor and piping. The user enters a job plan number and clicks the button for switching to the job standards program. The user then uses the logic and queries in the job standards program to identify nine operations required to complete the activity, each operation having been defined previously and being assembled to produce a new job plan. These are identified as follows.
Description: DISASSEMBLE SERVO MOTOR AND PIPING
Daily
Duration Prep
10 DRAIN OIL IN TO SUMP 1.61 0.12
20 REMOVE GREASE LINES 0.29 0.12
30 DISCONNECT SERVO LINK ARM 2.37 0.20
40 REMOVE SERVO PIPING 1.78 0.00
50 DISCONNECT RESTORING CABLE 0.28 0.00
60 RIG CRANE 0.75 0.00
70 ATTACH RIGGING TO SERVO MOTOR 0.74 0.00
80 REMOVE DOWEL PINS AND BOLTS 0.51 0.12
90 LIFT AND MOVE SERVO TO ASSEMBLY 0.86 0.00
CALCULATIONS Formula:
MAA Clock Time + (Sum of MAA Basic Prep Time)/Crew Size
For OP 10 1.53 hrs + (0.16 hrs)/2 man crew = 1.61 hrs
For OP 20 0.25 hrs + (0.08 hrs)/2 man crew = 0.29 hrs
For OP 30 2.24 hrs + (0.40 hrs)/3 man crew = 2.37 hrs
For OP 40 1.78 hrs + (0.00 hrs)/4 man crew = 1.78 hrs
For OP 50 0.28 hrs + (0.00 hrs)/2 man crew = 0.28 hrs
For OP 60 0.75 hrs + (0.00 hrs)/3 man crew = 0.75 hrs
For OP 70 0.69 hrs + (0.20 hrs)/4 man crew = 0.74 hrs
For OP 80 0.47 hrs + (0.08 hrs)/2 man crew = 0.51 hrs
For OP 90 0.86 hrs + (0.00 hrs)/4 man crew = 0.86 hrs
After this information is developed, the user then can return to the job planning screen where either the fields are filled in from this data or saved as a complete job plan in the job planning program. The user then prepares to produce a work order as follows. EXAMPLE WORK ORDER
Description: DISASSEMBLE SERVO MOTOR AND PIPING
Assume: Schedule Factor 2.0 One-way Travel = 0.4 hrs
Daily
Duration
Prep
10 DRAIN OIL INTO SUMP 3.46
0.24
20 REMOVE GREASE LINES 0.82
0.24
30 DISCONNECT SERVO LINK ARM 5.14
0.40
40 REMOVE SERVO PIPING 3.56
0.00
50 DISCONNECT RESTORING CABLE 0.56
0.00
60 RIG CRANE 1.50
0.00
70 ATTACH RIGGING TO SERVO MOTOR 1.48
0.00
80 REMOVE DOWEL PINS AND BOLTS 1.26
0.24
90 LIFT AND MOVE SERVO TO ASSEMBLY 1.72
0.00
999 TRAVEL 3.20
WORK ORDER CALCULATIONS
Step Op Description
Calculation
1. 10 Duration after Schedule Factor
1.61 hrs * 2.0 = 3.22 hrs
Daily Prep after Schedule Factor
0.12 hrs * 2.0 = 0.24 hrs
Total
3.46 hrs
20 Duration after Schedule Factor
0.29 hrs * 2.0 = 0.58 hrs
Daily Prep after Schedule Factor
0.12 hrs * 2.0 = 0.24 hrs
Total
0.82 hrs
30 Duration after Schedule Factor
2.37 hrs * 2.0 = 4.74 hrs
Daily Prep after Schedule Factor
0.20 hrs * 2.0 = 0.40 hrs
Total
5.14 hrs
40 Duration after Schedule Factor
1.78 hrs * 2.0 = 3.56 hrs
Daily Prep after Schedule Factor
0.00 hrs * 2.0 = 0.00 hrs
Total
3.56 hrs
50 Duration after Schedule Factor
0.28 hrs * 2.0 = 0.56 hrs
Daily Prep after Schedule Factor
0.00 hrs * 2.0 = 0.00 hrs
Total
0.56 hrs
60 Duration after Schedule Factor
0.75 hrs * 2.0 = 1.50 hrs
Daily Prep after Schedule Factor
0.00 hrs * 2.0 = 0.00 hrs
Total
1.50 hrs
70 Duration after Schedule Factor
0.74 hrs * 2.0 = 1.48 hrs
Daily Prep after Schedule Factor
0.00 hrs * 2.0 = 0.00 hrs
Total
1.48 hrs
80 Duration after Schedule Factor
0.51 hrs * 2.0 = 1.02 hrs
Daily Prep after Schedule Factor
0.12 hrs * 2.0 = 0.24 hrs
Total
1.26 hrs
90 Duration after Schedule Factor
0.86 hrs * 2.0 = 1.72 hrs
Daily Prep after Schedule Factor
0.00 hrs * 2.0 = 0.00 hrs
Total
1.72 hrs
2. For application of daily prep
10 Number of Days 3.22 hrs/8.0 hrs - (2 *
0.4 hrs) - 0.24 hrs
= 3.22 hrs/6.96 hrs
= 0.462
= 1.0 day
20 Number of Days 0.58 hrs/8.0 hrs - (2 *
0.4 hrs) - 0.24 hrs
= 0.58 hrs/6.96 hrs
= 0.08
= 1.0 day
30 Number of Days 4.74 hrs/8.0 hrs - (2 *
0.4 hrs) - 0.40 hrs
= 4.74 hrs/6.80 hrs
= 0.69
= 1.0 day
40 Number of Days 3.56 hrs/8.0 hrs - (2 *
0.4 hrs) - 0.00 hrs
= 3.56 hrs/7.20 hrs
= 0.49
= 1.0 day
50 Number of Days 0.56 hrs/8.0 hrs - (2 *
0.4 hrs) - 0.00 hrs
= 0.56 hrs/7.20 hrs
= 0.08
= 1.0 day
60 Number of Days 1.50 hrs/8.0 hrs - (2 *
0.4 hrs) - 0.00 hrs
= 1.50 hrs/7.20 hrs
= 0.21
= 1.0 day
70 Number of Days 1.48 hrs/8.0 hrs - (2 *
0.4 hrs) - 0.00 hrs
= 1.48hrs/7.20 hrs
= 0.21
= 1.0 day
80 Number of Days 1.02 hrs/8.0 hrs - (2 *
0.4 hrs) - 0.24 hrs
= 1.02 hrs/6.96 hrs
= 0.146
= 1.0 day
90 Number of Days 1.72 hrs/8.0 hrs - (2 *
0.4 hrs) - 0.00 hrs
= 1.72 hrs/7.20 hrs
= 0.24
= 1.0 day
3. For application of total travel time
Sum of all operations = (3.22 + 0.58 + 4.74 + 3.56 + 0.56 + 1.50 +
1.48 + 1.02 + 1.72) = 18.4 hrs
Sum of all daily prep = (0.24 + 0.24 + 0.40 +
0.24) = 1.12 hrs
Number of Days = 18.4 hrs/8.0 - (2 * 0.4
hrs) - 1.12 hrs
=
18.4 hrs/6.08 hrs
=
3.02
=
4.0 days
4. New Duration
For Op 10 3.22 hrs + (1.0 day * 0.24 hrs) =
3.46 hrs
For Op 20 0.58 hrs + (1.0 day * 0.24 hrs) =
0.82 hrs
For Op 30 4.74 hrs + (1.0 day * 0.40 hrs) =
5.14 hrs
For Op 40 3.56 hrs + (1.0 day * 0.00 hrs) =
3.56 hrs
For Op 50 0.56 hrs + (1.0 day * 0.00 hrs) =
0.56 hrs
For Op 60 1.50 hrs + (1.0 day * 0.00 hrs) =
1.50 hrs
For Op 70 1.48 hrs + (1.0 day * 0.00 hrs) =
1.48 hrs
For Op 80 1.02 hrs + (1.0 day * 0.24 hrs) =
1.26 hrs
For Op 90 1.72 hrs + (1.0 day * 0.00 hrs) =
1.72 hrs
5. Travel Time
For Op 999 Travel Time 4.0 days * (2 * 0.4
hrs) = 3.2 hrs
As described earlier, the job standards program will use the following steps to create a Job Plan: 1) Automatically generate an Operation Number for each operate step in the Job Plan. The first number will be 10. Subsequent operation numbers will be sequenced in increments of ten. 2) Select the Operation Description. This will be done by answering all questions required by the logic tree for creating Job Plans. The responses to these questions will generate the Operation Description with the associated time and labor. 3) If there are Job Preparation time associated with the Multi Activity Analysis, MAA, the times will be displayed in a Job Preparation window for each operation step. (See FIG. 3) The user will be asked whether to include preparation times, YES or NO. If Yes, then the time for all preparation except DAILY will be added to the operation duration. The Daily Prep will be carried over to the Job Plan as a separate entity. If No, then no preparation time will be added to the operation duration. The Daily Preparation will not be carried over to the Job Plan. After the Job Plan is stored in the job planning software database, the user can input only daily preparation in the Work Order Operations screen. The manually entered daily preparation must be reasonable and entered before the data is updated. 4) Do you want to add another Operation? If Yes, then the user returns to Step 1 to continue using the job standards logic tree to generated additional operation descriptions. 5) Do you want to save the Job Plan? If Yes, then a display of various crafts with crew size is presented, with a request to confirm or modify these. For example, the lead craft may be changed, with a request to modify the lead craft crew size. If the craft or crew size entered is other than what is displayed, the message "You are over-ridding values recommended by the job standards program, Do you want to continue?" will be displayed. If No, then the job standard program selections are reentered. If yes, then the user selected lead craft is used. If any tools and materials are associated with the selected operations, the planner will be asked to include all tools and materials. These can be supplied by drop down menu, or by part or tool number. If No, then the tools and materials are not added. If yes, then the job standards selected tools and materials will be added into the job plan. Once complete, the user exits from the job standards program and returns to the job planning program by clicking on a button, where the fields in the job plan are populated with the information generated in the job standards program, or the completed job plan is transferred in its entirety. To revise a Job Plan, the user has three actions that can be performed on an operation: add, delete, and modify. The user can add a new operation to an existing job plan by using the job standards program or by using the job planning program. The user can delete a complete operation in the Job Plan by using the job standards program, or can modify an operation in the Job Plan by using either program. To use the job standards program, the following steps may be used: 1) Display Job Plan in Job Plan Operation window. 2) Ask question: MODIFY, INSERT, or DONE IF, MODIFY THEN>Go to Step 3 IF, INSERT THEN>Go to Step 8 IF, DONE THEN>Go to Step 12 3) Select the Operation Number that the planner will modify. The Operation Number is a line entry in the Job Plan Operation screen that is associated with an operation description. 4) Ask: What is the ACTION for this operation? >Disassemble, Modification, Assemble >Site Inspection >Test Disassemble, Modification, Assemble contains the data driven logic, Site Inspection and Test are logic driven and select only specific MAA elements. The Operation Description will be selected by answering all questions required by the logic tree for revising Job Plans. The responses to the logic tree questions will generate the Operation Description. 5) Follow steps for creating a Job Plan for qualifying the MAA selected by the job standards program. 6) If a Long Description Key exists for this operation. The planner will be asked: Do you want to keep the LDKey for this operation? IF, No THEN>Delete LDKey when Job Plan is saved. IF, Yes THEN>Retain the current LDKey. 7) Go to Step 2. 8) Select an Operation Number. 9) Follow logic in Create a Job Plan in the job standards program. 10) Go to Step 2. 11) Do you want to save the Job Plan? IF, Yes THEN>Display up to 4 Crafts with crew size (See FIG. 4) >Request to modify Lead Craft. >Request to modify Lead Craft Crew size if Lead Craft is changed. >If the craft or crew size entered is other than what is displayed, the message "You are over-ridding values recommended by the job standards program, Do you want to continue?" will be displayed. If, No THEN>Go to Modify Lead Craft If, Yes THEN>Continue >If any Tools and Materials are associated with the selected operations, the planner will be asked to include all tools and materials. If, No THEN>Do not add Tools and Materials If, Yes THEN>Add Tools and Materials to the Job Plan >Insert data into job plan tables IF, No THEN>Control is returned to the welcome window. The user has the option to revise a Job Plan or EXIT. 12) The revision of a Job Plan is finished, control is returned to the job planning software. Utilizing the present invention, optimized job plans and work orders can be generated that accurately identify manpower, material and tool requirement. With optimized planning, delays are avoided and equipment downtime minimized. For routine, emergency and preventive maintenance, specific materials and tools can be rapidly identified and made available to complete operations in a timely manner. Further, sufficient flexibility is provided in standards development to accommodate the various day to day changes that occur, allowing changes to be incorporated into the job plan so that overall planning is not disrupted. By utilizing job standards logic, the user has an effective tool for avoiding errors in job planning. While preferred embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes or modifications can be made without varying from the scope of the invention.
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