Intelligent computer integrated maintenance system and method

An intelligent computer integrated maintenance system and method may be used with a group of machines which require maintenance, known as a "complex", such as a group of production lines each of which includes many production machines for producing a product. The intelligent computer integrated maintenance system includes an electronically stored parts manual which contains a hierarchical listing of all parts in the production machines. The hierarchical listing contains a complete bill of materials which breaks each machine into subassemblies and breaks each subassembly into its subassemblies down to the level of individual parts. The intelligent computer integrated maintenance system also includes a maintenance operations computer controller which includes a maintenance schedule management subsystem, an engineering change control subsystem, a parts manual management subsystem and a spares inventory management subsystem. The maintenance schedule management subsystem obtains a schedule of actual and planned production system and groups maintenance activities in order to minimize the lost production time for each complex. For example, maintenance is scheduled for off-line times for each complex if possible. Alternatively, if a number of maintenance tasks are scheduled for a short time interval, they may be grouped together so that they can be performed simultaneously. The engineering change control subsystem integrates engineering change activities with maintenance activities to maximize production time. The automated parts manual is also updated to account for engineering change controls. The spare parts inventory management subsystem orders spare parts based on predicted maintenance rather than on prescribed inventory levels. Just-in-time parts ordering is thereby facilitated. The computer integrated maintenance system and method of the present invention allows maintenance operations to be integrated into the complexes primary activity, such as production, in an intelligent manner. When used, production efficiency is maximized as is the use of available maintenance manpower. Engineering changes are easily accommodated and spare parts inventory is kept to a minimum.