Component Inspection Scheduling Based on Failure Impact
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Solution Overview
Problem
Existing equipment inspection systems do not consider the importance level of inspections for each component part, leading to potential misalignment in maintenance timing and frequency, which can result in either unnecessary or insufficient inspections.
Innovation Solution
An equipment inspection system that acquires influence indices such as MTTR and MTBF to determine the importance level of inspections for each component part, allowing for tailored inspection cycles based on the significance of failures, thereby optimizing maintenance timing and frequency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If inspections are performed at fixed intervals for all component parts, then maintenance scheduling is simplified, but inspection timing may be inappropriate for components with different failure impacts
Solution Approach 1:
The patent applies local quality by assigning different inspection cycles to different component parts based on their individual failure impact levels. High-importance components receive more frequent inspections while low-importance components receive less frequent inspections, allowing each component to be inspected at an appropriate timing rather than using a uniform schedule for all parts.
Solution Approach 2:
The patent implements dynamics by making inspection cycles adaptive rather than static. The inspection cycle for each component is dynamically adjusted based on its failure impact level, which is determined through historical failure data analysis. This allows the maintenance schedule to evolve and optimize over time based on actual component performance and failure patterns.
2Reliability
If inspection frequency is increased for all components, then equipment reliability is improved, but maintenance costs and time consumption increase
Solution Approach 1:
The patent applies local quality by differentiating inspection frequencies based on component importance. Critical components that significantly impact equipment operation receive more frequent inspections to ensure reliability, while non-critical components receive less frequent inspections, thereby reducing overall maintenance time consumption without compromising essential equipment reliability.
3Productivity
If inspection frequency is decreased for all components, then maintenance efficiency is improved, but some components may not be inspected at appropriate timings
Solution Approach 1:
The patent applies local quality by tailoring inspection frequencies to the specific needs of each component based on its failure impact. This ensures that critical components are inspected frequently enough to maintain reliability, while non-critical components are inspected less frequently, thereby improving overall maintenance efficiency without compromising the inspection timing appropriateness for important components.
Data Source
AI summary
An equipment inspection system capable of creating an inspection plan for inspecting a component part of an equipment at an appropriate timing is provided. An equipment inspection system includes an index acquisition unit, an importance level judgement unit, and an inspection time determination unit. The index acquisition unit acquires at least one influence index. The importance level judgement unit judges an importance level of an inspection on a component part based on the influence index. The inspection time determination unit determines the inspection time of the component part according to the importance level.