(19) United States
`(2) Patent Application Publication (10) Pub. No.: US 2002/0007297 A1
`Clarke
`(43) Pub. Date:
`Jan. 17, 2002
`
`US 20020007297A1
`
`(54) METHOD AND SYSTEM FOR ENTERPRISE
`
`WIDE PRODUCTION SCHEDULING
`
`(76) Inventor. Hernan Jose Clarke, Scottsdale, AZ
`(US)
`
`Correspondence Address:
`Alexander B. Ching
`Quarles & Brady Streich Lang LLP
`Renaissance One
`Two North Central Avenue
`Phoenix, AZ 85004 (US)
`
`(21) Appl. No.:
`(22) Filed:
`
`09/837,807
`Apr. 17, 2001
`
`
`
`-
`
`-
`
`-
`
`-
`
`Related U.S. Application Data
`(63) Non-provisional of provisional application No.
`60/197,954, filed on Apr. 17, 2000.
`Publication Classification
`
`-
`
`. -
`
`(51) Int. Cl." … G06F 17/60
`(52) U.S. Cl. … 705/8
`(57)
`ABSTRACT
`A computer implemented method and system for enterprise
`wide planning is disclosed. In an embodiment, one or more
`work card templates are initially defined. Then a plurality of
`work cards representing a project are received and compared
`with the work card templates. Scheduling parameters from
`the work card templates are added to the matching work
`cards. Then, expected non-routine work cards are added to
`the work cards. Next, the expected non-routing work cards
`and the operational work cards are scheduled.
`
`CiM Ex. 1045 Page 1
`
`

`
`Patent Application Publication
`
`Jan. 17, 2002 Sheet 1 of 14
`
`US 2002/0007297 A1
`
`
`
`100
`
`Database
`
`CiM Ex. 1045 Page 2
`
`

`
`Patent Application Publication
`
`Jan. 17, 2002 Sheet 2 of 14
`
`US 2002/0007297 A1
`
`202
`
`204
`
`206
`
`Pre Induction
`Phase
`
`
`
`
`
`Forecast Optimizer
`
`Work Completion
`
`Schedule
`
`
`
`
`
`Report Generator
`
`FIG. 2
`
`CiM Ex. 1045 Page 3
`
`

`
`Patent Application Publication
`
`Jan. 17, 2002 Sheet 3 of 14
`
`US 2002/0007297 A1
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`302
`
`Load Work Order
`
`Compare Work
`Cards to Template
`
`Assign Default
`Parameters from
`Templates
`
`Display Work Cards
`
`FIG. 3
`
`3.11
`
`Manually Assign
`Parameters
`
`CiM Ex. 1045 Page 4
`
`

`
`Patent Application Publication
`
`Jan. 17, 2002 Sheet 4 of 14
`
`US 2002/0007297 A1
`
`402
`
`404
`
`406
`
`Impart WO and
`Select WO
`
`
`
`Query DB for
`all WC
`
`
`
`Compare WCID with
`those in WC Template
`
`
`
`
`
`Insert
`Production
`Parameters
`
`NO 416
`
`YES
`
`412
`
`NO
`
`418
`WC S No
`Oependant?
`
`422
`NO
`
`426
`NO
`
`430
`
`END
`
`
`
`YES º ES
`
`Y
`
`Translate
`Zone
`
`YES
`
`Translate
`Skill
`
`FI G 4
`
`CiM Ex. 1045 Page 5
`
`

`
`Patent Application Publication Jan. 17, 2002 Sheet 5 of 14
`
`US 2002/0007297 A1
`
`
`
`502
`
`Query DB
`for Non-routines
`
`Compute Average
`Number of Min NR
`
`Optimize
`
`FIG. 5
`
`CiM Ex. 1045 Page 6
`
`

`
`Patent Application Publication
`
`Jan. 17, 2002 Sheet 6 of 14
`
`US 2002/0007297 A1
`
`weaoMW0s§§5.235
`m8mm»mocoNsoOE\as9oasvoEas
`
`illlll!I......-H3u.
`
`
`
`
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`
`
`
`
`
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`
`anmagéilla
`laéglagglasggglgglla
`
`
`E.!._!E.E..:...:!.E!EEIE
`
`E.§!_EE!a§..E§I_EanEIi:
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`
`E32.“églafiaggls.o:§mElH
`
`EcalaafléglfinufialaEgmlaawgglfiolfiala
`
`EslggégfimgglsalfialaE!g._EggmaEE!EuEEI_m
`'
`
`CiM Ex. 1045 Page 7
`
`CiM Ex. 1045 Page 7
`
`
`
`
`

`
`Patent Application Publication
`
`Jan. 17, 2002 Sheet 7 of 14
`
`US 2002/0007297 A1
`
`
`
`CiM Ex. 1045 Page 8
`
`

`
`Patent Application Publication Jan. 17, 2002 Sheet 8 of 14
`802
`
`US 2002/0007297 A1
`
`Query DB
`
`8 04
`
`822
`
`
`
`
`
`
`
`Complete
`WCQ
`
`850
`
`N
`Update Main
`Schedule Field
`
`Production
`Schedule
`
`Open Lot
`Update DB
`
`
`
`FIG. 8
`
`CiM Ex. 1045 Page 9
`
`

`
`Patent Application Publication
`
`Jan. 17, 2002 Sheet 9 of 14
`
`US 2002/0007297 A1
`
`
`
`
`
`
`
`
`
`
`
`Select Time Slice
`
`
`
`Compute Demand
`of Resource
`
`
`
`Compare
`Demand to
`Available
`
`Repeat for All WC
`
`
`
`Calculate Actual
`Use Reel, Display
`as Table
`
`902
`
`904
`
`906
`
`908
`
`910
`
`FIG. 9
`
`CiM Ex. 1045 Page 10
`
`

`
`Patent Application Publication Jan. 17, 2002 Sheet 10 of 14 US 2002/0007297 A1
`
`1006
`\\ Day 1
`01/01/2001
`
`Day 2
`01/02/2001
`
`1004
`
`
`
`
`
`
`
`Demand Available under over
`oilopool
`65 ||
`0
`|| – || 25
`o?o22001 ||
`40 || 50
`|| 0 || 0 |
`
`
`
`1010
`Resources
`
`FIG. 10
`
`CiM Ex. 1045 Page 11
`
`

`
`Patent Application Publication
`
`Jan. 17, 2002 Sheet 11 of 14 US 2002/0007297 A1
`
`Determine Demand
`
`
`
`1102
`
`
`
`
`
`1104
`
`1106
`
`Determine Available
`Man Hours
`
`Redistribute Work Cards
`Forward Leveling
`
`FIG. 11
`
`CiM Ex. 1045 Page 12
`
`

`
`Patent Application Publication
`
`Jan. 17, 2002 Sheet 12 of 14
`
`US 2002/0007297 A1
`
`1202
`
`1204
`
`1206
`
`1208
`
`121()
`
`1212
`
`Recieve Multiple
`Work Orders
`
`Calculate Demand
`
`Calculate Available
`Resources
`
`Move Work Cards
`Forward
`
`Forward Optimize
`
`Backwards Fill in
`
`FIG. 12
`
`CiM Ex. 1045 Page 13
`
`

`
`Patent Application Publication
`
`Jan. 17, 2002 Sheet 13 of 14
`
`US 2002/0007297 A1
`
`
`
`CiM Ex. 1045 Page 14
`
`

`
`Patent Application Publication
`
`Jan. 17, 2002 Sheet 14 of 14 US 2002/0007297 A1
`
`1408
`
`1416
`
`FIG. 15
`
`
`
`1410
`
`FIG. 14
`
`
`
`Set Near Critical
`Tolerance
`
`Compute Total
`Float
`
`Compute Total
`Buffer
`
`Schedule/Optimize
`Without Passing
`WC Past Critical
`Point
`
`CiM Ex. 1045 Page 15
`
`

`
`US 2002/0007297 A1
`
`Jan. 17, 2002
`
`METHOD AND SYSTEM FOR ENTERPRISE WIDE
`PRODUCTION SCHEDULING
`
`FIELD OF INVENTION
`
`[0001] This invention relates to the field of multitier
`software and more specifically to a method and system for
`enterprise wide production scheduling.
`
`BACKGROUND OF INVENTION
`
`[0002] Converting maintenance and engineering tasks in a
`long-range schedule into work packages with the large
`number of work cards, resource requirements, and con-
`straints driving the production of the work is one of the most
`complex and challenging duties faced by expert planners
`and schedulers.
`
`[0003] Historically, producing realistic schedules and esti-
`mating project completion dates has been difficult Much of
`this difficulty is due to the inability of planners and sched-
`ulers to accurately project the amount and extensiveness of
`repairs that routine inspection work will generate. For
`example, in some large maintenance industries, there is a
`series of inspections that is performed on the unit being
`serviced at the beginning of every maintenance event. It is
`from these inspections that planners and schedulers deter-
`mine the actual amount of work required to complete the
`required maintenance project. However, modern planning
`systems fail to utilize this information in a meaningful way.
`What is needed is a planning system that takes into account
`historical knowledge.
`
`SUMMARY OF THE INVENTION
`
`In accordance with the teachings of the present
`[0004]
`inventions, method and system for enterprise wide produc-
`tion and scheduling is provided. The method and system of
`the present invention provides advantage over previously
`developed planning and scheduling techniques.
`
`implemented
`a computer
`In one embodiment
`[0005]
`method and system for enterprise wide planning is dis-
`closed. In an embodiment, one or more work card templates
`are initially defined. Then a plurality of work cards repre-
`senting a project are received and compared with the work
`card templates. Scheduling parameters from the work card
`templates are added to the matching work cards. Then,
`expected non-routine work cards are added to the work
`cards. Next, the expected non-routing work cards and the
`operational work cards are scheduled.
`
`[0006] A technical advantage of the present system is that
`expected non-routine work cards can be added. Additionally,
`what-if analysis and forecasting can be easily done. Addi-
`tional technical advantages can be readily apparent from the
`following figures, description and claims.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0007] For a more complete understanding of the present
`invention and advantages thereof, reference is now made to
`the following descriptions, taken in conjunction with the
`following drawings, in which like reference numerals rep-
`resent like parts, and in which:
`
`[0008]
`system;
`
`FIG. 1 is a block diagram of a computer network
`
`[0009] FIG. 2 is a block diagram of the modules of the
`planning application in accordance with the teachings of the
`present invention;
`
`[0010] FIG. 3 is a flowchart illustrating the loading of a
`new work order into the system;
`
`[0011] FIG. 4 is a flowchart illustrating the comparison of
`a work card from a work order to work card templates;
`
`[0012] FIG. 5 illustrates the injection of the non-routine
`work cards;
`
`[0013] FIG. 6 is a screen shot showing an exemplary work
`card center;
`
`[0014]
`
`FIG. 7 is a production schedule screen shot;
`
`[0015] FIG. 8 is a flow chart illustrating the production
`and control phase;
`
`[0016]
`process;
`
`FIG. 9 is a flowchart illustrating the forecasting
`
`[0017] FIG. 10 illustrates an exemplary schedule with a
`forecast table;
`
`[0018]
`zation;
`
`FIG. 11 illustrates a flowchart for leveling optimi-
`
`[0019] FIG. 12 is a flowchart illustrating the optimization
`of multiple work charts;
`
`[0020] FIG. 13 is a screen shot of an alternative view of
`the schedule FIG. 14 illustrates a task bar; and
`
`[0021] FIG. 15 is a flowchart of buffer threshold sched-
`uling.
`
`DETAILED DESCRIPTION OF THE DRAWINGS
`
`[0022] Turning first to the nomenclature of the specifica-
`tion, the detailed description which follows is represented
`largely in terms of processes and symbolic representations
`of operations by conventional computer components,
`including a central processing unit (“CPU”) or processor
`associated with a general purpose computer system, memory
`storage devices for the CPU, and connected pixel-oriented
`display devices. These operations include the manipulation
`of data bits by the CPU and the maintenance of these bits
`within data structures resident in one or more of the memory
`storage devices. Such data structures impose a physical
`organization upon the collection of data bits stored within
`computer memory and represent specific electrical or mag-
`netic elements. These symbolic representations are the
`means used by those skilled in the art of computer program-
`ming and computer construction to most effectively convey
`teachings and discoveries to others skilled in the art.
`
`[0023] For the purposes of this discussion, a process or
`method is generally considered to be a sequence of com-
`puter-executed steps leading to a desired result. These steps
`generally require manipulations of physical quantities. Usu-
`ally, although not necessarily, these quantities take the form
`of electrical, magnetic, or optical signals capable of being
`stored,
`transferred, combined, compared or otherwise
`manipulated. It is conventional for those skilled in the art to
`refer to these signals as bits, values, elements, symbols,
`characters, text, terms, numbers, records, files, or the like. It
`should be kept
`in mind, however,
`that these and others
`should be associated with appropriate physical quantities for
`
`CiM Ex. 1045 Page 16
`
`CiM Ex. 1045 Page 16
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`

`
`US 2002/0007297 A1
`
`Jan. 17, 2002
`
`computer operations, and that these terms are merely con-
`ventional
`labels applied to physical quantities that exist
`within and during operation of the computer.
`
`In addition, it should be understood that the pro-
`[0024]
`grams, processes, methods, etc. described herein are but an
`example of one implementation of the present invention and
`are not related or limited to any particular computer, appa-
`ratus or computer language. Rather, various types of general
`purpose computing machines or devices may be used with
`programs constructed in accordance with the teachings
`described herein. Similarly, it may prove advantageous to
`construct a specialized apparatus to perform the method
`steps described herein by way of dedicated computer sys-
`tems with hardwired logic or programs stored in non-volatile
`memory, such as read-only memory.
`
`[0025] Referring now in more detail to the drawings, FIG.
`1 is a diagram illustrating a planing and scheduling system
`100 including at least one client computer 102, a remote
`server 104 and remote database 106. Planing and scheduling
`system 100 includes the interface between remote server 104
`and at least one client computer 102. For example, planing
`and scheduling system 100 includes an interconnection
`between client computer 102 and remote server 104 through
`a communication line 108. Computer network 100 also
`includes the interface between remote server 104 and remote
`
`database 106 (not illustrated) through a plurality of com-
`munication lines 110. This allows client computer 102 to
`access content stored on the remote database 106 via remote
`
`server 104. While FIG. 1 shows only one client computer
`102, other clients can also be interconnected with remote
`server 104.
`
`[0026] Remote server 104 is a computer such as a personal
`computer,
`file server, workstation, minicomputer, main-
`frame, or any other computer capable of communicating and
`interconnecting with other computers. Remote server 104
`may include a processor, a printer, an input device such as
`a mouse and/or a keyboard, a monitor, a floppy disk drive,
`memory, a modem, and a mass storage device such as a hard
`disk drive. Communication lines 110 and communication
`
`lines 108 may be any type of communication link capable of
`supporting data transfer. For example, these communication
`lines may include any combination of an Integrated Services
`Digital Network (“ISDN”) communication line, a hard-
`wired line, a telephone link, a digital subscriber line, a cable
`connection, a fiber optic link or a wireless connection.
`
`[0027] Client computer 102 may be similar to remote
`server 104 and may be implemented using virtually any type
`of computer. Client computer 102 may be a personal com-
`puter having a processor, a printer, an input device such as
`a mouse and/or a keyboard, a monitor, a floppy disk drive,
`memory, a modem, and a mass storage device such as a hard
`disk drive. Client computer 102 and remote server 104 will
`be operating under the control of an operating system such
`as MS-DOS, Macintosh OS, WINDOWS NT, WINDOWS
`95/98/2000, OS/2, UNIX, XENIX, LINUX, BEOS and the
`like. Client computer 102 and remote server 104 each may
`utilize a different operating system. Client computer 102 and
`remote server 104 may execute any number of available
`application programs such as a web browser or web server.
`
`[0028] Client computer 102 may communicate through
`server 104 using the Internet. For example, in the case where
`remote server 104 is configured as a web server, client
`
`computer 102, generally using a web browser application
`program, may couple to remote server 104 and provide the
`address or uniform resource locator (URL) of an Internet
`web page. Remote server 104 in response transmits the
`Internet web page back to client computer 102 using a web
`browser.
`
`In operation, client computer 102 is a client tier
`[0029]
`running a web browser program to access a web site serviced
`by remote server 104. Remote server 104 is a middle tier
`running a production scheduling application. Client com-
`puter 102 accesses the application using a web browser or
`similar program. In the present invention, the application
`provides for planning and scheduling and utilizes a pre-
`induction module, a forecast module, a work completion
`module, a scheduling module and a report generation mod-
`ule. A user of client computer 102 is able to access and use
`the application using client computer 102. Client computer
`102 accesses the application and through the use of infor-
`mational screens supplied by remote server 104, the user is
`able to perform planning and scheduling tasks. Remote
`database 106 is a backend tier that can store the historic data
`
`from previous work orders as well as current work orders,
`where work orders are a complete set of maintenance or
`repair tasks that need to be done.
`
`[0030] Although network interconnection 100 has been
`illustrated and described in FIG. 1 as being a node or
`interconnection on the Internet, network interconnection 100
`may be any interconnection found on any computer network
`such as a local area network (“LAN”), a wide area network
`(“WAN”), an intranet, such as a corporate intranet, or any
`other communications and data exchange system created by
`connecting two or more computers. The present invention
`will be illustrated and described with an implementation
`using the Internet, however, it should be understood that the
`present invention is not limited to only implementations
`using the Internet.
`
`[0031] FIG. 2 is a block diagram of the modules of the
`planning application in accordance with the teachings of the
`present invention. Illustrated are a pre-induction module
`202, a forecast/optimization module 204, a work completion
`module 206 and a report module 208. These modules
`interact and work with a schedule module 210.
`
`[0032] Pre-induction module 202 is responsible for load-
`ing in the information regarding the various tasks that will
`define a complete job or inspection. In the present invention,
`individual tasks are represented as work cards. A job that
`may include many individual tasks, such as the inspection of
`an aircraft, are represented by work orders. Thus a work
`order consists of a collection of work cards. A schedule is
`
`produced from the work cards, their dependency on each
`other, the availability of resources and other factors.
`
`[0033] Forecast/optimization module 204 allows a user to
`manipulate the schedule in order to perform “what-if”
`analysis on the schedule produced by schedule module 210.
`Also, forecasting can be done. Forecasting is done to project
`what might happen based on resource constraints such as
`tools or manpower.
`
`[0034] Work completion module 206 receives updates
`from a worker or supervisor. In one embodiment,
`these
`updates are work cards whose designated tasks have been
`completed. When work cards are completed they are
`
`CiM Ex. 1045 Page 17
`
`CiM Ex. 1045 Page 17
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`

`
`US 2002/0007297 A1
`
`Jan. 17, 2002
`
`removed from active views on the schedule. Other updates
`may include additional work cards representing additional
`tasks that are non-routine or are modifications to the work
`order or other work cards.
`
`[0035] The schedule module 210 generates schedules
`based on information received from the other modules. The
`
`schedule is typically displayed graphically. For example,
`each work card can be displayed with the start and stop date
`displayed as part of a task bar on a graph. Also, schedule
`module performs scheduling and planning using a critical
`path method with or without using a buffered threshold.
`
`[0036] Report module 208 is used to format, generate and
`publish reports based on the planning and scheduling done
`by the other modules. Report module 208 features the ability
`to quickly design a report template, fill it with data and
`publish it to a remote server in a standard format.
`
`[0037] The following description of the production sched-
`uling invention will use aircraft inspection and maintenance
`as an example. It is obvious to those skilled in the art,
`however, that the present invention can be used to track the
`maintenance and inspection of any machinery as well as be
`used for other planning purposes.
`
`step 304, each work card in the work order is compared to
`work cards in the work card template. FIG. 4 illustrates this
`process in detail. In step 306, it is determined if the work
`order work cards match a work card template. This process
`is more fully discussed in FIG. 4. If there is a match, the
`work cards in the work order are assigned the values from
`the work card template in step 308. As mentioned before,
`these values may include the priority, milestone codes, and
`production dates and hours. After this is done, in step 310,
`the work cards from the work order are inserted into a flow
`
`generator and the work cards are displayed, typically sorted
`by production date and hour. If there is no match in step 306,
`the unmatching work cards are sent to a “bucket” so that the
`user can manually enter the important data in step 311. A
`“bucket” is a file that collects the unmatched work cards
`
`until the scheduling information is entered. Different types
`of buckets exist for different types of work cards.
`
`[0043] FIG. 4 is a flowchart illustrating the comparison of
`a work card from a work order to work card templates. In
`step 402, a work order is imported and selected. Then, in
`step 404, the work order is queried to extract all work cards.
`Then, in step 406, the work card identification numbers from
`the work order’s work cards are compared with the work
`card identification numbers from the work cards in the work
`
`[0038] Pre-Induction Phase
`
`card template.
`
`In order to start the planning and scheduling pro-
`[0039]
`cess, information regarding the work that needs to be done
`should be imported and characterized. The present invention
`uses two concepts for the work to be complete; the work
`card and the work order. The work card defines a specific
`task to be performed. A work card, in one embodiment
`contains a description of the job, the sequence of the job,
`which is an index of the work cards as layout in the proper
`order, the day and how the job is to be done, the shift the job
`is to be done such as graveyard or swing, the status of the
`job, the job priority, the milestone code for the job, which
`indicates the phase of execution of the job, the type of job,
`the work card number, the zone of the job which indicates
`where on the workpiece the job is to be done, the skill of the
`worker required to do the job,
`the estimated man-hours
`needed to complete the jobs and the actual numbers used to
`complete the job. Obviously,
`these are only exemplary
`categories and can change depending on the workpiece that
`is being worked on as well as other factors.
`
`[0040] A work order is a collection of work cards that
`define a complete task, such as a comprehensive inspection
`or a maintenance procedure. Awork order also includes such
`information as the start date and time of the work,
`the
`location of the work, an identification of what the work piece
`is, the number of work cards in the job and the number of
`unfinished work cards.
`
`[0041] Prior to loading a work order into the system, an
`initial user first forms a plurality of work card templates.
`Work card templates are work cards that a user has already
`pre-entered information onto such as shift, priority, zone,
`skill, sequence and even how long the work might take. This
`is done before any work orders are loaded into the system.
`The information entered is based on historical information
`
`for the task and is entered by planning experts.
`
`[0042] FIG. 3 is a flowchart illustrating the loading of a
`new work order into the system. In a first step 302, one or
`more work orders are loaded from a work order database. In
`
`In step 408 it is determined if there is a match. If
`[0044]
`so, in step 410 the production parameters from the work card
`template are copied over to the work order’s work card. In
`step 412 it is determined if that was the last work card to
`check for. If not, more work cards are compared in step 406.
`
`If, in step 408, the identification did not match, in
`[0045]
`step 414 it is determined if more work cards need to be
`checked. If so, they care checked in step 406. If not, in step
`416 the process ends.
`
`[0046] Turning back to step 412, if there are no more work
`cards to match, the matching work cards are checked to see
`if a work card is dependent on another. If a work card has
`a dependency, the dependent work cards are linked together.
`A work card is dependent if its execution depends on the
`execution of another work card. For example, a pair of work
`cards may be finish-to-start linked. That is, the beginning of
`one work card can not start until another work card is
`
`completed. Also, work cards can be start-to-start linked.
`That is, the work cards must start at the same time. While
`these examples show two linked work cards, any number of
`work cards can be linked using any linking relationship.
`Other dependency may include finish-to-finish and finish-
`to-start. A link may incorporate a lag or lead time that
`requires the start or finish of a linked work card after a
`certain amount of delay or before a certain amount of delay.
`
`[0047] After checking for dependent work cards, in step
`422 the zone description is checked to see if it matches the
`zone description in the work card template. The zone is a
`location on the work piece, such as an aircraft. Different
`users may use different terms for a zone. For example, one
`user might use the term cockpit for a particular zone while
`another user may use the designation Al for cockpit. If the
`zone description differs between the work order’s work card
`and the work card template, the zone description in the work
`order’s work card is changed to match the work card
`template’s zone description. In step 426, the skill description
`of the work order’s work card is compared to the work card
`
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`template. If there is a non-match, the work order’s work card
`skill description is changed to match the work orders tem-
`plate description in step 428. The comparison process then
`ends in step 430.
`
`cannot be completed due to a lack of resources such as tools
`or parts. The suspended work cards will stay in suspension
`until an unsuspend work card event is received in place of
`the suspended work card.
`
`[0048] After all the work cards are evaluated and either
`scheduled or sent to a holding bucket for later data entry, the
`present invention is able to adding expected non-routine
`work cards to the work cards of the work order. Expected
`non-routine work cards are tasks that, while not part of the
`work order, have historically arisen in conjunction with a
`given work order or work card. For example, a scheduled
`work order may call for the inspection of fan blades.
`Typically, when this occurs, the bolts holding on the cowl
`over the fan blades need replacement. The replacement is
`not part of the work order but arises enough to be an
`expected non-routine task. Knowing this information helps
`to make a more accurate schedule. FIG. 5 illustrates the
`
`injection of the non-routine work cards. In a first step 502,
`the external database 106 is queried for historical non-
`routines associated with a previously completed work order.
`Then, in step 504 the average minutes of a non-routine task
`is computed for each non-routine work card associated with
`the work order. In step 506, the work order receives the
`expected non-routine work order. Then,
`the demand and
`availability of resources such as man-hours are measured
`and the schedule is optimized using this information in step
`508. Further details on optimization can be found in con-
`junction with FIG. 510. In step 512 the optimized schedule
`is set as the initial baseline schedule.
`
`[0049] FIG. 6 is a screen shot showing an exemplary work
`card center 600. In this illustration, a number of work cards
`502 are illustrated as a series of rows, with each row
`representing a different work card 602 for a different task.
`The collection of work cards 602 is the work order 604.
`
`Screen shot also includes an open box 604, which is selected
`to open an existing work order. Import button 606 is used to
`import a work order. Update button 608 is selected to update
`a work order. A work order might need updating when
`additional jobs are found related to the work order once the
`job starts. Additional tasks may be assigned to the work
`order by an engineer working on the project. Once a work
`order is loaded and displayed on a work card center 600, the
`update button 608 changes color to indicate an update is
`available for that work order. When the update button 608 is
`selected, the additional work cards are added to the work
`order. Selecting non-routine button 610 will bring up a
`listing of non-scheduled, non-routine work cards. Non-
`routine jobs are additional jobs found when the work order
`is being executed. These jobs represents additional work that
`is not usually part of the work order. For example, an
`inspection of a jet engine for a particular work order, a stress
`crack in a fan blade might be found. This would lead to a
`number of non-routine work cards to fix the fan blade.
`
`[0050] Modification button 612 is selected to view non-
`scheduling modifications to work orders. Modifications are
`work cards that represent engineering orders that represent
`changes to what is done by a work order. When the modi-
`fications are uploaded to the work center,
`they can be
`assigned production schedule parameters such as shifting
`production day and production time. Then the modification
`job cards are added to the already scheduled work cards.
`
`[0051] Suspend button 614 is selected to view suspended
`work cards. A suspended work card is a work card that
`
`[0052] Routine button 616 is selected to view unscheduled
`routine job cards. Typically, these work cards are ones that
`were not matched to a pre-existing work card template.
`These need to have the production schedule parameters
`assigned. After that, they can be scheduled. Sequence button
`617 sorts the card by sequence number, which is an index of
`the work card in the execution order. Sort button 619 allows
`
`sorting on any of the work cards fields.
`
`[0053] Work card list 620 is a list of work cards in the
`current work list 604.
`
`[0054] Work order box 622 lists the name of the current
`work order. Start date/time box 624 lists the start date and
`time the work is to begin and end date/time box 625 lists the
`end of the work order. Location box 626 lists the location
`
`where the maintenance is being performed. Aircraft type box
`628 lists the specific type of aircraft such as DC10 or
`MD-L1011. In embodiments where other machinery besides
`aircraft is being worked on, this box will have a different
`name. Tail number box 630 lists the tail number of the
`
`aircraft that is assigned to a specific craft. Model number
`box 632 lists the model number of the aircraft. Operation
`day box 634 lists the overall day of the maintenance pro-
`cedure. Total cards box 636 lists the number of work cards
`502 for the work order 604. This is the number of work cards
`
`assigned to the project. Open cards box 638 lists the number
`of uncompleted work cards 602 in the work order 604.
`
`[0055] Card set 640 allows the user to chose to se either all
`work cards, open (or pending) work cards or the closed
`(completed) work cards.
`
`[0056] Check flow generator tab 642 allows a user to
`select the check flow generator screen, which is displayed in
`FIG. 7, check view tab 644 is selected to display a graphical
`representation of the schedule. Report generator tab 646 is
`selected to start the report generator, discussed in further
`detail later. WC template 648 is selected to start the WC
`template set up which allows the user to enter production
`parameters to a template in order to preflow the work cards.
`
`[0057] FIG. 7 is a production schedule screen shot 700. It
`is displayed by selecting the check view tab 644 after a work
`order 604 has been loaded. Schedule 702 shows a job 704
`that includes its name 706 and a bar 708 indicating how long
`the project is scheduled to last. The placement of the job on
`the table corresponds to the start hour and date. The view can
`be set to view a schedule for any number of days selecting
`day view box 710.
`
`[0058] Planning and Control Phase
`
`In the planning and control phase, workers perform
`[0059]
`each task on the work cards. As tasks are performed, the
`progress can be entered on terminals at the repair location.
`This will update the database with the completed work
`cards. Also, non-routine work cards, suspended work cards
`and modification work cards can be entered at this time. All
`of this will then be entered into the work order database.
`
`[0060] FIG. 8 is a flow chart illustrating the production
`and control phase. In step 802, a work order database is
`populated. In one embodiment, this can occur when a user
`
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`of external production computer 112 enters information. In
`step 804, the update to the work order is loaded into the
`client computer 102 by a user selecting the update button
`608 from the work card center 600. The update and new
`work cards are loaded into the system.
`
`In step 806, work cards are examined to determine
`[0061]
`of it
`is a non-routine work card. If the work card is
`
`non-routine in step 816 it is determined if the non-routine
`work cards match any of the estimated non-routines already
`in the remote database 106. If so, in step 818 the non-routine
`cards replace the estimated non-routine cards. If there is no
`match in 816, then the non-routine work cards are placed in
`a bucket to be manually entered.
`
`In step 808 it is determined if the work card is a
`[0062]
`suspended card. If so, in step 820 it is determined if the
`suspended card is dependent or linked to othe