A SYSTEM AND METHOD FOR DIGITIZING INSPECTION AND MAINTENANCE PROCESSES WITH AI AND AR INTEGRATION

Abstract

ABSTRACT The present invention relates to a system and method for automating and enhancing the inspection, maintenance, and construction workflows through advanced integration of Internet of Things (IoT) sensors, augmented reality (AR), artificial intelligence (AI), building management systems (BMS), and enterprise resource planning (ERP) systems. The system comprises an IoT-enabled sensor array that collects real-time environmental and equipment data, which is then processed by an AI module to predict maintenance needs and optimize workflows. The system utilizes an AR interface to provide real-time, step-by-step guidance for inspections, while seamlessly integrating with BMS and SAP billing systems for real-time environmental monitoring, task scheduling, and automated financial reconciliation. Additionally, a human resources (HR) portal interface is incorporated to assign tasks based on personnel expertise and availability. The method facilitates predictive maintenance, improves operational efficiency, and ensures streamlined task management through integration with multiple technologies, enabling enhanced automation and decision-making in industrial environments.

Specification

Description:TECHNICAL FIELD
[0001] The present invention relates to a system and method for digitizing and automating inspection and maintenance processes across various industries. More particularly, it pertains to a comprehensive digital solution that integrates building management systems (BMS), artificial intelligence (AI), augmented reality (AR), and human resources (HR) portals to streamline, monitor, and manage inspection and maintenance tasks. Further, the present invention discloses a platform that enhances operational efficiency, safety compliance, and predictive maintenance capabilities by providing real-time insights, guided inspections, and skill-based task assignments, thereby reducing downtime and optimizing asset performance.
BACKGROUND
[0002] In the rapidly evolving landscape of industrial inspection, maintenance, and construction, the need for efficient, data-driven systems has become increasingly critical. Traditional processes often rely on paper-based workflows or standalone digital tools, leading to fragmented data management and limited real-time insights. With advancements in automation, artificial intelligence, and digital infrastructure, industries have an opportunity to transition from these outdated practices to integrated solutions that streamline every stage of the inspection and maintenance lifecycle. The importance of a unified system that can manage inspections from raw material sourcing to post-sale customer feedback has become evident as companies strive to improve operational efficiency, safety, and compliance.
[0003] Conventional methods available for inspection and maintenance management are typically manual or involve separate tools for different stages, such as initial inspections, scheduled maintenance, and error reporting. These disconnected processes pose multiple challenges, including high labor costs, increased likelihood of human error, delayed reporting, and inconsistent data. Additionally, the lack of real-time monitoring, predictive analytics, and centralized data makes it challenging to optimize maintenance schedules and track equipment conditions effectively. To address these technical problems, there is a need for a system that consolidates various inspection stages into a seamless workflow and provides actionable insights for proactive maintenance.
[0004] Further, the existing systems merely focus on isolated functions, such as equipment inspection or maintenance scheduling, without comprehensive integration of advanced technologies like AR, AI, VR, or IoT-enabled monitoring. They often overlook key aspects such as lifecycle tracking, BMS integration, financial reconciliation through SAP Billing, and workforce coordination via HR portals. Consequently, these systems fall short in offering end-to-end solutions that can cover every step of the process from material sourcing and manufacturing to sales, feedback, and error resolution.
[0005] As a result, there is a need for a system and method that not only integrates advanced technologies for real-time inspection and maintenance but also connects each phase of the appliance lifecycle. Such an approach would ensure high standards of quality, safety, and operational efficiency, addressing the limitations of conventional methods by offering an all-encompassing solution.
[0006] Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through the comparison of described systems with some aspects of the present disclosure, as set forth in the remainder of the present application and with reference to the drawings.
SUMMARY
[0007] In an embodiment, a method for integrated inspection, maintenance, and construction monitoring is disclosed. In one example, the method includes initiating an inspection by scanning a barcode to identify the equipment or area, followed by using an AR-enabled interface to guide the user through customized inspection checklists based on the specific item. Further, the method incorporates AI-driven predictive analytics to assess historical and real-time data, predicting maintenance needs and scheduling tasks accordingly. Additionally, VR technology can be employed for virtual training simulations, allowing personnel to perform mock inspections. The method also includes real-time data synchronization with a Building Management System (BMS) for monitoring environmental factors, integration with SAP Billing to automate financial tracking, and an HR portal link to ensure task allocation matches personnel expertise. This comprehensive approach enables seamless tracking, reporting, and error resolution across all stages, from raw material acquisition to post-sale feedback, enhancing overall efficiency and operational accuracy.
[0008] In an embodiment, a system for integrated inspection, maintenance, and construction monitoring is disclosed. In one example, the system comprises a platform that consolidates various stages of appliance lifecycle management, including raw material purchasing, manufacturing, sales, and post-sale feedback. The system further integrates advanced technologies such as Augmented Reality (AR), Artificial Intelligence (AI), and Virtual Reality (VR) to assist with real-time inspections and predictive maintenance. Additionally, the system is linked with Building Management Systems (BMS), SAP Billing, and HR portals to streamline operations, ensure accurate billing, and optimize workforce allocation. Such an approach enables seamless tracking, reporting, and error resolution across all inspection and maintenance tasks.
BRIEF DESCRIPTION OF DRAWINGS
[0009] The accompanying drawings illustrate the various embodiments of systems, methods, and other aspects of the disclosure. Any person with ordinary skills in the art will appreciate that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one example of the boundaries. In some examples, one element may be designed as multiple elements, or multiple elements may be designed as one element. In some examples, an element shown as an internal component of one element may be implemented as an external component in another, and vice versa. Further, the elements may not be drawn to scale.
[0010] Various embodiments will hereinafter be described in accordance with the appended drawings, which are provided to illustrate and not to limit the scope in any manner, wherein similar designations denote similar elements, and in which:
[0011] FIG. 1 is a block diagram illustrating the system environment 100 in which various embodiments of the present invention may be implemented.
[0012] FIG. 2 is a flowchart that illustrates a method to enhance safety management processes using AI-enabled technology, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0013] The present disclosure may be best understood with reference to the detailed figures and description set forth herein. Various embodiments are discussed below with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions given herein with respect to the figures are simply for explanatory purposes as the methods and systems may extend beyond the described embodiments. For example, the teachings presented and the needs of a particular application may yield multiple alternative and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond the particular implementation choices in the following embodiments described and shown.
[0014] References to "one embodiment," "at least one embodiment," "an embodiment," "one example," "an example," "for example," and so on indicate that the embodiment(s) or example(s) may include a particular feature, structure, characteristic, property, element, or limitation but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element, or limitation. Further, repeated use of the phrase "in an embodiment" does not necessarily refer to the same embodiment.
[0015] The present invention addresses the limitations of conventional inspection and maintenance methods by providing an integrated system that streamlines the entire lifecycle of appliance management, from raw material procurement to post-sale feedback. The system combines advanced technologies, such as AR, AI, VR, and IoT, to offer real-time monitoring, predictive maintenance, and immersive inspection experiences. It integrates Building Management Systems (BMS) for environmental and operational efficiency, SAP Billing for seamless financial tracking, and an HR portal for optimized workforce coordination. The system further consolidates data from all stages, ensuring comprehensive reporting, error resolution, and improved decision-making, thereby enhancing operational efficiency, safety, and compliance across industries.
[0016] The primary objective of the present subject matter is to provide a system and method for integrated inspection, maintenance, and construction monitoring, capable of managing every stage of the appliance lifecycle, from raw material purchasing to post-sale feedback and error resolution. To achieve this, the present invention aims to leverage advanced technologies such as Augmented Reality (AR), Artificial Intelligence (AI), Virtual Reality (VR), Building Management Systems (BMS), SAP Billing, and HR portal integration, creating a unified, data-driven solution that enhances operational efficiency, reduces downtime, and improves the accuracy of inspections and maintenance tasks. The system's objective is to automate and streamline the inspection process by providing real-time data collection, predictive maintenance capabilities, and multi-phase reporting to ensure timely, cost-effective decision-making. By integrating IoT-enabled sensors, the system continuously monitors equipment conditions and alerts users to potential failures before they occur, ensuring proactive maintenance. Additionally, the present invention seeks to provide customizable checklists for various inspection and maintenance tasks, enhancing flexibility and ensuring that all necessary steps are performed consistently. It also aims to improve team collaboration through features such as joint inspections, issue reporting, and managerial oversight, fostering greater accountability and reducing errors across all stages of the process. As such, the present invention strives to offer an all-encompassing, scalable solution that not only improves inspection and maintenance efficiency but also integrates seamlessly with other operational systems, thus providing a holistic approach to asset management and lifecycle optimization.
[0017] The present invention is an integrated system and method for managing inspection, maintenance, and construction processes across the entire appliance lifecycle from raw material procurement through manufacturing, sales, and post-sale feedback. The present invention uniquely combines advanced technologies such as Augmented Reality (AR), Artificial Intelligence (AI), Virtual Reality (VR), IoT-enabled sensors, Building Management Systems (BMS), SAP Billing, and HR portals into a cohesive platform. By linking these technologies, the system offers real-time monitoring, predictive maintenance, lifecycle tracking, and automated task management, addressing the inefficiencies of traditional paper-based or disconnected digital methods. Through AR and VR, technicians receive visual, step-by-step guidance for complex inspections, while AI modules predict maintenance needs based on real-time data and historical trends. The system's BMS integration enhances operational oversight by aligning maintenance schedules with environmental conditions, and SAP Billing automates financial processing related to inspections, reducing administrative workload. The comprehensive and seamless integration of these advanced features into a single platform provides an end-to-end solution that enables proactive maintenance, accurate lifecycle monitoring, and streamlined financial and workforce management. Such an approach addresses gaps in conventional systems, delivering enhanced efficiency, safety, and decision-making for industries reliant on rigorous inspection and maintenance workflows.
[0018] In an embodiment, the present invention's process inspection system is designed to cover multiple inspection stages within a single process, such as logistics and manufacturing, ensuring thorough evaluation from the origin point to the final user. For instance, in logistics, the system can track inspections across each transportation stage, storing data for every checkpoint and capturing any discrepancies or issues. In manufacturing, the system inspects at different production stages, from raw material intake to packaging, aligning each stage with specific quality metrics.
[0019] In another embodiment of the present invention, the system discloses the construction context, wherein the project is divided into tasks and sub-tasks, with each segment linked to a project ID. As tasks and sub-tasks progress, inspections are conducted and logged under the respective ID, generating comprehensive reports and performance metrics. Integrating billing portals with this platform enables automatic approval of completed tasks, sub-tasks, and inspections, ensuring accurate billing in real-time. Additionally, the system includes a "Report Issue" feature, enabling team members at any level to report observed issues, which are then directed to the relevant managers for prompt resolution, documented in real-time to enhance accountability and streamline repairs.
[0020] FIG. 1 is a block diagram illustrating the system architecture 100 of the integrated inspection, maintenance, and construction monitoring platform in which various embodiments of the present invention may be implemented. The system environment 100 generally includes an Inspection Management Module 102, a Predictive Analytics Engine 104, a Communication Network 106, an Augmented Reality (AR) Interface 108, a Building Management System (BMS) Integration Module 110, an SAP Billing Interface 112, and an HR Portal Integration 114. Each of these components is interconnected through the communication network 106, enabling seamless data exchange and operational integration across all stages of inspection and maintenance tasks.
[0021] In accordance with the present invention, the Inspection Management Module 102 acts as the inspection process, enabling digital tracking and standardization of all inspection-related activities. Equipped with QR or barcode scanning, it allows users to quickly identify specific appliances, machinery, or areas to be inspected, retrieving relevant information and checklists associated with each item. The module automates the inspection workflow by guiding users through customized, step-by-step procedures tailored to each asset type, ensuring consistent and comprehensive inspection across all items. Such type of module also logs data on each inspection, creating a robust record that facilitates tracking, compliance, and future analysis.
[0022] In accordance with the present invention, the Predictive Analytics Engine 104 is the platform's intelligent functionality, analyzing inspection data and real-time sensor inputs to predict equipment failures and maintenance needs. This engine leverages machine learning modals to assess historical patterns, environmental conditions, and operational data, offering insights that help predict when specific components may need attention. By identifying potential issues before they arise, the Predictive Analytics Engine helps reduce unplanned downtime, optimize maintenance schedules, and ultimately extend the operational lifespan of assets. It also provides actionable recommendations that support proactive maintenance planning.
[0023] In accordance with the present invention, the Communication Network 106 underpins the system's interconnected infrastructure, facilitating seamless data exchange among the various modules, including the Inspection Management Module 102, Predictive Analytics Engine 104, and AR Interface 108. Supporting a range of protocols such as Wi-Fi, Bluetooth, and potentially cellular connections, this network ensures real-time transmission of data, from sensor readings and inspection logs to user interactions. The Communication Network 106 enables the system's remote access capabilities and integration with mobile applications, enhancing flexibility and allowing for monitoring and control from various locations, ultimately contributing to the system's overall adaptability.
[0024] In accordance with the present invention, the Augmented Reality (AR) Interface 108 enhances the user experience during inspections by providing a visual overlay of critical information and digital instructions. The module assists users by displaying step-by-step guidelines, operational status indicators, and specific areas that need attention. The AR Interface projects relevant data directly onto the equipment or location, reducing guesswork and improving inspection accuracy. By offering visual support, this module also accelerates the inspection process, minimizes human error, and reduces the training time required for new personnel, ensuring that inspections are both accurate and efficient.
[0025] In accordance with the present invention, the Building Management System (BMS) Integration Module 110 synchronizes the inspection and maintenance platform with facility management systems, allowing the system to factor in environmental variables such as temperature, humidity, and energy usage. Such an integration enables intelligent scheduling of maintenance tasks, adjusting to real-time environmental conditions to reduce wear and tear on equipment. By aligning with the BMS, this module also allows for optimized energy management, enhanced operational efficiency, and the ability to anticipate and address potential issues before they impact facility performance.
[0026] In accordance with the present invention, the SAP Billing Interface 112 integrates financial tracking with the inspection and maintenance activities, ensuring accurate accounting and cost allocation for each task. By linking directly with SAP Billing, the module automates billing processes, allocates costs to the correct maintenance or inspection task, and provides real-time financial data to stakeholders. Such automation reduces administrative work, enhances accuracy, and enables more detailed reporting on maintenance-related expenses. The SAP Billing Interface streamlines the financial aspects of maintenance and inspection, allowing organizations to track costs effectively and make data-driven financial decisions.
[0027] In accordance with the present invention, the HR Portal Integration 114 is responsible for coordinating workforce management within the platform. It tracks personnel availability, assigns tasks based on skill level, monitors performance, and logs training requirements, ensuring that each inspection or maintenance task is completed by qualified personnel. Additionally, the HR portal supports collaborative tasks such as joint inspections, issue reporting, and managerial oversight, fostering accountability and efficient task management. Such type of module enhances workforce productivity by ensuring the right people are assigned to the right tasks, contributing to overall operational efficiency.
[0028] As according to the present invention, the said modules create a unified, end-to-end platform for managing the inspection, maintenance, and construction monitoring lifecycle. The combination of AR, AI-driven predictive analytics, and seamless communication across systems like BMS, SAP Billing, and the HR portal provides a comprehensive solution that automates routine tasks, enhances accuracy, reduces downtime, and optimizes both human and material resources. As such, the present system offers a modernized approach to asset management, targeting improved performance, safety, and longevity of equipment across various industries.
[0029] In an embodiment, the AR module plays an essential role by offering real-time, visual guidance during inspection and maintenance tasks. Through an AR-enabled interface, users can access step-by-step checklists and visual overlays specific to the equipment or area being inspected. For example, when a user scans an asset barcode, the AR interface displays customized instructions, enabling precise and guided inspections. As such, the said component enhances accuracy, minimizes human error, and ensures consistency across inspection tasks, particularly in complex or safety-critical environments.
[0030] In an embodiment, the AI module is used for predictive maintenance and data-driven decision-making in the system. It processes historical and real-time data to predict maintenance needs, reducing unplanned downtime. Using machine learning modules, it analyzes patterns in equipment usage, environmental conditions, and past failures to forecast maintenance intervals. This module enables proactive scheduling and enhances the overall reliability of assets, ensuring that potential issues are addressed before they lead to costly failures. Additionally, AI-based analytics provide actionable insights, helping managers optimize asset performance and lifecycle.
[0031] In an embodiment, the VR module supports training and skill development for personnel by simulating inspection and maintenance scenarios in a virtual environment. This allows employees to undergo immersive, hands-on training without physical risks or resource constraints. By familiarizing personnel with equipment and inspection procedures through VR simulations, the system ensures that users are well-prepared for real-world inspections, improving task accuracy and safety. VR simulations also enable management to assess skills, ensuring that only qualified personnel are assigned to specific tasks.
[0032] Further, integrating with Building Management Systems (BMS), the said module monitors environmental factors such as temperature, humidity, and energy consumption, which may impact asset conditions. The BMS integration enables real-time data collection on the facility's operational environment, helping to align maintenance schedules with environmental conditions. For example, if an asset is sensitive to temperature fluctuations, the BMS can alert the system to schedule inspections when deviations occur. This integration ensures that maintenance activities are not only timely but also based on contextual factors that affect asset health.
[0033] Furthermore, the SAP Billing integration streamlines financial management by automating the tracking of inspection and maintenance expenses. Such a component links inspection tasks with corresponding costs, facilitating real-time financial reconciliation and reducing administrative burden. By automating billing processes, this module ensures accurate tracking of maintenance-related expenditures and enables cost forecasting, providing financial visibility that aids budget planning and cost optimization across the inspection lifecycle.
[0034] In an embodiment, the HR portal integration ensures that inspection and maintenance tasks are assigned based on personnel expertise and availability. Such a component enables task allocation that matches the skills of the workforce, improving operational efficiency. For example, specific inspections may require personnel with specialized certifications or training, which the HR portal identifies and assigns accordingly. Additionally, it streamlines workforce management by coordinating schedules and tracking task completion, ensuring accountability and optimal resource utilization.
[0035] In an embodiment, the IoT sensors play an essential role in the system's real-time monitoring capabilities. By continuously tracking parameters like temperature, vibration, and usage levels, these sensors provide constant feedback on equipment conditions. The IoT data feeds directly into the system, where it is analyzed for abnormalities that might signal potential failures. This continuous monitoring not only supports predictive maintenance but also alerts users to possible issues before they escalate, enabling proactive intervention that enhances asset longevity and safety.
[0036] In an embodiment, the lifecycle tracking module consolidates data from each stage of the asset's lifecycle, from raw material sourcing to post-sale feedback and error resolution. Such a module allows managers to monitor and document the entire lifecycle of each asset, ensuring compliance, quality assurance, and streamlined process control. By tracking lifecycle data, this component enables detailed analysis of an asset's history, aiding in decisions regarding replacements, upgrades, and performance improvements.
[0037] In an embodiment, the Data Analytics and Reporting Module aggregates and analyzes data from various sources, including inspection reports, maintenance logs, and sensor readings, to provide comprehensive insights into asset performance and maintenance needs. It generates customized reports for stakeholders, highlighting trends, potential risks, and areas for improvement. The data analytics module aids in strategic decision-making by providing actionable insights that enhance asset utilization and operational efficiency.
[0038] Further, the present invention provides customizable checklists which are a practical feature that ensures inspections are thorough and specific to each asset type. This module allows managers to design tailored checklists that align with regulatory requirements, safety standards, and operational needs. The checklists are accessible via the AR interface, ensuring that all necessary steps are completed during inspections. This customization feature improves inspection quality and consistency, reducing errors and enhancing compliance.
[0039] Further, the issue-reporting module of the present invention allows personnel to document and report any discrepancies or errors identified during inspections. It facilitates real-time communication and ensures that issues are recorded, tracked, and resolved promptly. This module integrates with the lifecycle tracking system, providing a record of issue history, resolutions, and any recurring patterns, which aids in addressing root causes and improving asset reliability over time.
[0040] In an exemplary operation, a system to facilitate comprehensive inspection, maintenance, and construction monitoring integrates advanced technologies to streamline processes, improve accuracy, and enhance operational efficiency. The system comprises an Inspection Management Module that enables standardized, digital tracking of inspection tasks through QR or barcode scanning, allowing users to identify and retrieve relevant data for each item being inspected. The system also includes a Predictive Analytics Engine that processes inspection data and real-time sensor inputs, leveraging machine learning to predict equipment failures and optimize maintenance schedules. Additionally, a Communication Network supports seamless data exchange among system components, enabling remote monitoring and real-time updates via various communication protocols such as Wi-Fi, Bluetooth, and cellular connections. In an embodiment, the system further incorporates an Augmented Reality (AR) Interface, which overlays step-by-step instructions and operational data directly onto the equipment during inspections, minimizing errors and expediting the inspection process.
[0041] In another embodiment, the Building Management System (BMS) Integration Module synchronizes with environmental controls, adjusting maintenance scheduling based on real-time conditions and optimizing energy usage. The SAP Billing Interface automates cost allocation and financial tracking, linking inspection and maintenance activities directly to financial records. Additionally, in an embodiment, an HR Portal Integration manages workforce assignments, ensuring tasks are allocated based on personnel availability and skill levels. Together, these components create an intelligent, end-to-end platform that supports proactive asset management, reduces downtime, and maximizes resource efficiency across various operational environments.
[0042] In another embodiment, the present invention provides a system that integrates real-time data visualization and remote collaboration tools to enhance inspection, maintenance, and construction monitoring tasks. This embodiment incorporates a Centralized Dashboard, accessible from any device, that consolidates and displays real-time data from various inspection sites, offering users comprehensive insights into asset conditions, maintenance schedules, and task statuses. The system includes Remote Collaboration Modules that allow field technicians and off-site experts to connect via live video and AR overlays, enabling remote guidance, troubleshooting, and skill development. In this embodiment, the system further incorporates a Virtual Reality (VR) Training Platform that simulates complex inspection and repair scenarios, enabling personnel to train on new procedures and equipment safely and efficiently. A Data Analytics Module continuously evaluates historical and real-time data from IoT sensors, identifying patterns and anomalies that signal potential failures, which prompts predictive maintenance actions. The system also includes Automated Reporting and Compliance Check Modules that generate detailed reports based on regulatory standards, automatically flagging deviations or potential issues. This embodiment thus provides a robust solution that facilitates informed decision-making, reduces human error, and promotes collaborative workflows, ultimately enhancing operational continuity and safety across inspection and maintenance environments.
[0043] In yet another embodiment, the present invention offers a fully integrated, AI-driven platform that emphasizes predictive insights and lifecycle management for inspection, maintenance, and construction operations. This embodiment includes an AI-powered diagnostic Module that continuously analyzes sensor data to detect early signs of wear, malfunction, or performance degradation across assets. When anomalies are detected, the system generates automated alerts and suggests preemptive maintenance actions, minimizing the risk of unexpected downtime. A Digital Twin Component enables real-time simulation of asset behavior, allowing users to visualize operational impacts and optimize maintenance strategies by mirroring real-world conditions in a virtual environment. Furthermore, this embodiment features Workflow Automation, which standardizes task assignment, tracking, and completion across departments, ensuring timely updates and reducing bottlenecks in inspection and maintenance workflows. Integrated with a Knowledge Management Database, the system also provides instant access to technical manuals, previous maintenance records, and solution guides, empowering technicians with resources at their fingertips. Lastly, a Compliance Monitoring System tracks adherence to safety and operational standards, generating compliance reports and notifying users of regulatory lapses or missed inspections. This embodiment thus provides a proactive, data-driven approach to asset management that improves efficiency, reduces costs, and enhances regulatory compliance across industries.
[0044] Consider a practical scenario to illustrate the workings of the present disclosure. Imagine a manufacturing plant equipped with complex machinery that requires routine inspection, maintenance, and compliance checks to ensure operational efficiency. In this scenario, the plant's maintenance team uses the disclosed system to initiate an inspection on a critical piece of equipment by scanning its barcode, which immediately identifies the machine and loads its maintenance history, current operational status, and custom inspection checklist onto an AR-enabled device. As the technician follows the AR-guided steps, the system's AI module analyzes sensor data in real time, assessing equipment performance and alerting the technician to any potential issues. If the AI identifies an anomaly, such as a component showing signs of wear, it triggers predictive maintenance protocols, automatically scheduling a replacement task in the workflow system and ordering the required parts. Simultaneously, the system records each inspection step, ensuring compliance with industry standards, and synchronizes data with the Building Management System (BMS) to adjust the environment as needed for optimized machine performance. Upon completion, the system generates a report, logs it in the centralized database for future reference, and updates the SAP Billing system with any financial transactions linked to parts and labor. This seamless integration allows the plant to maintain high operational standards, reduce downtime through proactive maintenance, and streamline workflow management, showcasing the effectiveness of the disclosed invention in a real-world industrial setting.
[0045] FIG. 2 is a flowchart that illustrates a method for integrating and automating inspection, maintenance, and construction processes, in accordance with an embodiment of the present disclosure. The method begins in a Start step 202 and proceeds to step 204. At step 304, the system initiates the inspection process by scanning a barcode or QR code on the equipment or area to be inspected, thereby identifying the specific item and retrieving its associated data. Step 306 follows, where the AR-enabled interface presents a customized inspection checklist, tailored to the equipment or area based on the retrieved data. At step 308, the user follows the AR-guided instructions, performing the inspection steps while the system collects real-time sensor data, such as temperature, pressure, or vibration, from IoT-enabled devices embedded in the equipment. Step 310 involves the AI-driven predictive analytics module analyzing the collected data and comparing it to historical trends to predict maintenance needs or potential failures. If a potential issue is detected, step 312 is triggered, where the system automatically schedules a maintenance task or alerts the technician for further investigation. Step 314 involves real-time data synchronization with the Building Management System (BMS) to adjust environmental conditions that may impact equipment performance. At step 316, the system integrates with the SAP Billing module to track parts, labor, and other financial aspects related to the maintenance task. Step 318 follows, where the system links with the HR portal to assign tasks based on the skill set of the available personnel. The method concludes at step 320, where the system generates a report documenting the inspection, maintenance actions, and any required follow-ups, ensuring compliance and providing detailed records for future reference.
[0046] At step 204, the system identifies the equipment or area to be inspected by scanning a barcode or QR code, typically located on the asset. This scan triggers the retrieval of all relevant information associated with that specific asset, such as historical inspection data, maintenance records, sensor statuses, and operational parameters. The use of barcodes or QR codes in this step enhances operational efficiency by allowing for quick identification and real-time access to the asset's lifecycle data, facilitating precise inspection processes.
[0047] At step 206, a customized Inspection Checklist via AR is disclosed. Once the asset is identified, the system displays a customized inspection checklist on the Augmented Reality (AR) interface. The said checklist is dynamically generated based on the specific equipment type, condition, and prior maintenance history. The AR interface overlays this checklist in the user's field of view, guiding the inspector step-by-step through the inspection process. The advanced feature here is the real-time adaptability of the AR system, which adjusts the checklist based on the live condition of the asset, allowing for efficient and thorough inspections with minimal human error.
[0048] At step 208, Data Collection through IoT Sensors is disclosed. As the inspection proceeds, the system collects real-time data from various IoT-enabled sensors embedded in the equipment. These sensors continuously monitor key parameters such as temperature, pressure, vibration, and humidity, providing precise, up-to-the-minute readings. Such type of data is fed into the system for immediate analysis. The advanced feature in this step is the integration of predictive maintenance sensors, which can detect early signs of wear and potential failures by analyzing anomalies in the sensor data compared to baseline parameters. This allows for proactive intervention before a fault occurs.
[0049] At step 210, AI-Driven Predictive Analytics is disclosed. The data collected from IoT sensors is analyzed by an Artificial Intelligence (AI) module that employs machine learning modals to detect patterns, anomalies, and potential issues. The AI module compares the real-time data with historical data to predict future maintenance needs or failures. The predictive analytics feature leverages vast amounts of historical data, enabling the system to forecast when components will likely need maintenance, thus minimizing downtime and optimizing maintenance scheduling. Additionally, the AI can identify the root causes of recurring issues, providing valuable insights for long-term equipment optimization.
[0050] At step 212, maintenance Task Scheduling or Alert Generation is disclosed. Based on predictive analytics, if a potential failure is identified, the system automatically generates a maintenance task. This task can be scheduled based on priority and the predicted severity of the issue. If the issue is critical, the system may alert the technician immediately, providing details of the potential failure, necessary actions, and required parts. The advanced feature here is the system's ability to automatically trigger a sequence of events, from scheduling maintenance to issuing alerts, thus reducing manual intervention and enabling faster response times.
[0051] At step 214, Data Synchronization with a Building Management System (BMS) is disclosed. The system synchronizes with the Building Management System (BMS) to monitor environmental conditions such as temperature, humidity, and ventilation that might impact equipment performance. This integration ensures that the maintenance process aligns with environmental conditions that could influence the equipment's operation or repair requirements. For example, if temperature conditions are outside optimal ranges, the BMS can adjust HVAC settings to maintain proper operating conditions during maintenance, ensuring safe and effective work environments.
[0052] At step 216, Integration with the SAP Billing Module is disclosed. After the maintenance task is completed, the system integrates with the SAP Billing module to track and manage the financial aspects of the inspection and maintenance processes. This includes tracking the costs associated with parts, labor, equipment usage, and other resources. The advanced feature here is the automation of financial tracking, ensuring that invoices are generated accurately and that all costs related to the task are properly documented in real time. This reduces the administrative burden and ensures seamless reconciliation of financial data.
[0053] At step 218, Task Assignment through the HR Portal is disclosed. At this step, the system interfaces with the HR portal to ensure that maintenance tasks are assigned to qualified personnel based on their skills and availability. The HR system checks for the appropriate skill set and experience level required for the task and schedules the technician accordingly. The advanced feature here is the ability to dynamically adjust task assignments based on real-time personnel availability, ensuring that the most qualified individual is dispatched to perform the task and that resources are optimized.
[0054] At step 220, the Generation of Inspection and Maintenance Report is disclosed. After the maintenance is completed, the system generates a detailed report documenting the inspection findings, the actions taken, and any follow-up tasks required. This report includes insights such as sensor data, AI predictions, maintenance history, and cost tracking. The advanced feature in this step is the automated generation of comprehensive reports that can be customized to meet specific regulatory, safety, and operational standards. These reports provide actionable insights for future planning and ensure full traceability and compliance, all of which contribute to improved decision-making and asset management.
[0055] In one embodiment, the system integrates seamlessly with third-party software applications, extending its functionalities beyond inspection and maintenance. Such type of integration allows the system to interact with other business operations, such as procurement, sales, and customer support, thereby offering a holistic solution to enterprise management. For example, the SAP Billing module can communicate with inventory management software to automatically update stock levels when materials are purchased for maintenance, or it can coordinate with customer relationship management (CRM) systems to schedule follow-up inspections or maintenance for clients. This integration ensures that the inspection system works in tandem with the broader operational framework of the organization, improving overall efficiency and coordination across departments.
[0056] In another embodiment, the system employs IoT sensors to monitor various operational parameters of equipment, such as temperature, vibration, or pressure. These sensors continuously collect real-time data and relay it to the processing unit, which analyzes the data against predefined thresholds. If a sensor detects an abnormal reading, such as a rise in temperature beyond safe limits or unusual vibrations indicating potential mechanical failure, the system triggers an early warning for the maintenance team. This early warning enables proactive intervention, preventing equipment breakdowns before they occur and minimizing unplanned downtime. The IoT sensors can also be integrated with the system's AI module to refine predictive maintenance models over time, improving accuracy with each data point collected.
[0057] In yet another embodiment, the system utilizes advanced AI modules that leverage machine learning models to continuously refine and improve predictive maintenance capabilities. These modules process both historical and real-time data from the IoT sensors and other system modules to detect patterns that indicate potential failures. Over time, as more data is collected, the system becomes better at predicting when specific components or equipment may fail, allowing for more precise maintenance scheduling. For example, if the system detects a pattern of reduced equipment performance or frequent minor failures, it can recommend a preventive maintenance schedule to address the issue before it escalates, thereby extending the lifespan of the equipment and minimizing costly repairs.
[0058] In a further embodiment, the HR portal module is configured to enhance task assignment efficiency by considering personnel availability and proximity to the inspection site. When an inspection task is initiated, the system analyzes the availability of relevant personnel based on their schedules and the distance between their current location and the equipment requiring inspection. The system then assigns the task to the most appropriate individual, ensuring that inspections are completed promptly and that resources are optimally utilized. Such a dynamic assignment process helps improve operational efficiency, reduce response times, and ensure that personnel are not overburdened, ultimately leading to better performance and higher employee satisfaction.
[0059] In another embodiment, the present system provides a multi-stage process inspection framework that enables thorough inspections at various stages within a single project. For example, within logistics processes, the system tracks and inspects items as they move from one checkpoint to another. Each checkpoint inspection is recorded under a unique project ID, allowing seamless traceability across the logistics chain. In a manufacturing context, the system inspects items at critical junctures from raw material intake to finished product dispatch. Each stage is documented, ensuring consistency and compliance across all levels of production. This multi-stage inspection feature not only ensures detailed quality control but also enables comprehensive tracking and timely reporting of issues that may arise at any point in the process, thereby improving reliability and reducing defects.
[0060] Yet another embodiment of the present invention. The tasks of construction projects are subdivided into multiple stages, and each task requires specific inspections to ensure quality and adherence to standards. The system assigns a unique project ID to each construction project, under which all tasks and sub-tasks are cataloged. Each sub-task, such as laying foundations, erecting walls, or installing electrical wiring, is associated with a corresponding inspection schedule. As each inspection is completed, the system records the results, enabling streamlined report generation and providing a basis for billing approvals. Such a modular task-inspection integration facilitates seamless project management, as supervisors can monitor task completion, verify inspection status, and authorize billing based on completed stages.
[0061] In a further embodiment, the system's billing module is integrated with inspection tracking, allowing billing approvals based on verified completion of specific tasks or sub-tasks. Once a particular construction or maintenance task is inspected and approved, the system automatically updates the billing portal, creating a seamless bridge between project management and financial accounting. By linking inspection completion with billing, the system reduces administrative overhead, minimizes delays, and ensures that billing reflects the true status of the project. Such integrated workflow between inspection and billing not only enhances operational efficiency but also supports accurate financial tracking and reporting.
[0062] In another embodiment, the present system includes a Report Issue feature that allows users to document and escalate issues identified during any inspection. When a problem is noted such as a defect in materials, a safety hazard, or a deviation from project specifications the user can immediately log the issue within the system, which tags it with the relevant project ID, location, and inspection stage. This issue-reporting function enhances accountability by ensuring that issues are recorded in real-time, allowing for prompt corrective actions. Additionally, the system can generate an aggregated report of reported issues, which supervisors and managers can use to address recurring problems or areas needing attention.
[0063] The present disclosure offers several technical advantages over conventional systems, primarily by integrating multiple sensor technologies, including IoT-enabled sensors, ultrasonic sensors, and GPS modules. This enhanced sensor integration allows for real-time data collection from various equipment, providing comprehensive environmental awareness and precise asset monitoring. Additionally, the use of advanced AI-driven predictive analytics enables the system to identify potential issues before they escalate, reducing downtime and optimizing maintenance schedules. The incorporation of Augmented Reality (AR) for customized inspection checklists enhances user interaction and ensures efficient, error-free inspections. Furthermore, seamless synchronization with Building Management Systems (BMS) and SAP Billing modules ensures operational efficiency across the maintenance process, from task scheduling to financial tracking. The automated task assignment through the HR portal optimizes resource allocation, while the generation of comprehensive inspection and maintenance reports provides actionable insights for continuous improvement. These technical advancements collectively enable a more intelligent, efficient, and proactive approach to asset management and maintenance.
[0064] The present disclosure provides a solution to a significant technical problem in the field of inspection and maintenance management, specifically addressing the inefficiencies of traditional systems. By integrating advanced technologies such as Augmented Reality (AR), Artificial Intelligence (AI), Internet of Things (IoT)-enabled sensors, and Building Management Systems (BMS), the system enables real-time monitoring, predictive maintenance, and lifecycle tracking across various stages of appliance management. The system offers specific technical features, such as AR-driven inspection checklists for guided, error-free inspections, AI-powered predictive analytics for proactive maintenance scheduling, and IoT-enabled sensors for continuous condition monitoring. Additionally, the integration with SAP Billing automates financial tracking, while the HR portal optimizes workforce coordination by aligning tasks with personnel expertise. These functionalities streamline the entire inspection, maintenance, and construction process, significantly improving operational efficiency, reducing downtime, enhancing safety, and ensuring compliance with regulatory standards.
[0065] A person with ordinary skills in the art will appreciate that the systems, modules, and sub-modules have been illustrated and explained to serve as examples and should not be considered limiting in any manner. It will be further appreciated that the variants of the above-disclosed system elements, modules, and other features and functions, or alternatives thereof, may be combined to create other different systems or applications.
[0066] Those skilled in the art will appreciate that any of the aforementioned steps and/or system modules may be suitably replaced, reordered, or removed, and additional steps and/or system modules may be inserted, depending on the needs of a particular application. In addition, the systems of the aforementioned embodiments may be implemented using a wide variety of suitable processes and system modules, and are not limited to any particular computer hardware, software, middleware, firmware, microcode, and the like. The claims can encompass embodiments for hardware and software or a combination thereof.
[0067] While the present disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed, but that the present disclosure will include all embodiments falling within the scope of the appended claims.
, Claims:CLAIMS
We Claim:
1. A system for digitizing and automating inspection and maintenance processes, the system comprising:
a platform configured to integrate multiple technologies, including Augmented Reality (AR), Artificial Intelligence (AI), Building Management Systems (BMS), Internet of Things (IoT)-enabled sensors, Virtual Reality (VR), SAP Billing, and Human Resource (HR) portals;
an AR-enabled interface configured to display customized inspection checklists and provide step-by-step guidance for inspections across various equipment, areas, and stages;
an AI module configured to process historical and real-time data to predict maintenance needs and schedule tasks dynamically, based on evolving process conditions and requirements;
an IoT sensor module configured to monitor the condition of equipment continuously, with real-time data analytics for predictive maintenance and failure alerts;
an integrated BMS module configured to synchronize inspection data with environmental and operational factors, optimizing maintenance schedules in alignment with changing conditions;
an HR portal interface configured to assign inspection tasks to personnel based on expertise, availability, and task urgency, ensuring skill-appropriate and timely assignments;
an SAP Billing interface configured to track financial aspects of inspection and maintenance processes, enabling accurate cost allocation, billing, and integration with other financial portals for seamless financial oversight, wherein the SAP Billing interface is further configured to integrate with external billing portals, enabling automated billing upon inspection and task completion, facilitating seamless financial tracking and management aligned with project milestones; and
a Report Issue module configured to enable users to document and escalate issues identified during inspections, logging each report with relevant project ID, inspection stage, and location details.

2. The system of claim 1, wherein the platform is further configured to support multi-stage process inspections across logistics or manufacturing stages, wherein each stage, from origin to destination, or from raw material intake to final product dispatch, is associated with a unique project ID for tracking and reporting.

3. The system of claim 1, wherein the AR-enabled interface provides immersive inspection experiences, further configured to use VR technology for simulation-based training and inspection rehearsal.

4. The system of claim 1, wherein the AI module is further configured to generate actionable insights to optimize asset performance, minimize operational downtime, and recommend customized inspection intervals based on real-time and historical data patterns.

5. The system of claim 1, wherein the HR portal interface tracks personnel performance metrics, including inspection efficiency and task completion rates, and dynamically updates task assignments that maximize workflow efficiency.

6. The system of claim 1, further comprising a task and sub-task management module for dividing construction projects into tasks and sub-tasks, each associated with distinct inspection points under a single project ID which provides structured report generation and accurate billing approval upon inspection completion.

7. A method for digitizing and automating inspection and maintenance processes, the method comprising:
initiating an inspection by scanning a barcode or QR code to identify the equipment, area, or stage for inspection within a multi-stage process flow;
using an AR-enabled interface to guide a user through a customized inspection checklist tailored to the specific item and stage being inspected;
collecting real-time data from IoT sensors embedded in the equipment, environment, or infrastructure, and analyzing the data using AI modules to predict maintenance needs and generate alerts for potential failures;
synchronizing the inspection data with a Building Management System (BMS) to align maintenance schedules with environmental and operational conditions;
assigning inspection tasks to personnel through an HR portal based on expertise, availability, and task criticality, ensuring optimal resource allocation;
tracking and managing financial aspects of the inspection process through an SAP Billing interface, enabling accurate cost allocation and reporting in conjunction with billing portals;
logging issues identified during inspections using a Report Issue module, wherein each reported issue is tagged with project ID, inspection stage, and location for real-time resolution tracking;and
generating performance reports for personnel based on inspection task completion, efficiency metrics, and logged issue resolutions, wherein the HR portal records these metrics to optimize workforce deployment and performance evaluation.

8. The method of claim 7, further generating real-time alerts for detected equipment malfunctions and deviations from operational standards based on IoT sensor data.

9. The method of claim 7, wherein the AI module includes predictive models that analyze historical inspection records, real-time conditions, and equipment usage patterns to recommend optimal maintenance intervals.

10. The method of claim 7, further comprising a task and sub-task management module that organizes a construction project into a hierarchy of tasks and sub-tasks, each requiring inspection and reporting under a unique project ID.

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