Implementing intelligent asset management systems (IAMS) within an industry 4.0 manufacturing environment

9th IFAC Conference on Manufacturing Modelling, Management and Control, MIM 2019; Berlin; Germany; 28 August 2019 through 30 August 2019. Publicado en IFAC-PapersOnLine 52(13), p. 2488-2493This paper aims to define the different considerations and results obtained in the implementation in an Intelligent Maintenance System of a laboratory designed based on basic concepts of Industry 4.0. The Intelligent Maintenance System uses asset monitoring techniques that allow, on-line digital modelling and automatic decision making. The three fundamental premises used for the development of the management system are the structuring of information, value identification and risk management

Integration of cost-risk assessment of denial of service within an intelligent maintenance system

As organisations become richer in data the function of asset management will have to increasingly use intelligent systems to control condition monitoring systems and organise maintenance. In the future the UK rail industry is anticipating having to optimize capacity by running trains closer to each other. In this situation maintenance becomes extremely problematic as within such a high-performance network a relatively minor fault will impact more trains and passengers; such denial of service causes reputational damage for the industry and causes fines to be levied against the infrastructure owner, Network Rail. Intelligent systems used to control condition monitoring systems will need to optimize for several factors; optimization for minimizing denial of service will be one such factor. With schedules anticipated to be increasingly complicated detailed estimation methods will be extremely difficult to implement. Cost prediction of maintenance activities tend to be expert driven and require extensive details, making automation of such an activity difficult. Therefore a stochastic process will be needed to approach the problem of predicting the denial of service arising from any required maintenance. Good uncertainty modelling will help to increase the confidence of estimates. This paper seeks to detail the challenges that the UK Railway industry face with regards to cost modelling of maintenance activities and outline an example of a suitable cost model for quantifying cost uncertainty. The proposed uncertainty quantification is based on historical cost data and interpretation of its statistical distributions. These estimates are then integrated in a cost model to obtain accurate uncertainty measurements of outputs through Monte-Carlo simulation methods. An additional criteria of the model was that it be suitable for integration into an existing prototype integrated intelligent maintenance system. It is anticipated that applying an integrated maintenance management system will apply significant downward pressure on maintenance budgets and reduce denial of service. Accurate cost estimation is therefore of great importance if anticipated cost efficiencies are to be achieved. While the rail industry has been the focus of this work, other industries have been considered and it is anticipated that the approach will be applicable to many other organisations across several asset management intensive industrie

Tutoring electronic troubleshooting in a simulated maintenance work environment

A series of intelligent tutoring systems, or intelligent maintenance simulators, is being developed based on expert and novice problem solving data. A graded series of authentic troubleshooting problems provides the curriculum, and adaptive instructional treatments foster active learning in trainees who engage in extensive fault isolation practice and thus in conditionalizing what they know. A proof of concept training study involving human tutoring was conducted as a precursor to the computer tutors to assess this integrated, problem based approach to task analysis and instruction. Statistically significant improvements in apprentice technicians' troubleshooting efficiency were achieved after approximately six hours of training

A Framework of an Intelligent Maintenance Prognosis Tool

The technology of prognosis has become a significant approach but its implementation in maintenance has a major extension. The ability prognosis in the medical area has been established to estimate the future of human health. However, in maintenance, application of prognosis is not yet seen as a practical use for making better maintenance decision. To date, research in this area has been done in proposing prognosis techniques or model but leaving the implementation of prognosis as their future work. In this paper, an overview of prognosis in maintenance is presented. By using the data-driven approach, a framework for implementing of an intelligent maintenance prognosis tool is introduced. The framework utilizes the existing equipment operating performance data in the industry for prognosis process. Next, the framework combines the ability of prognosis in estimating remaining useful life (RUL) of equipment with the maintenance action knowledge to generate a well-received maintenance plan

Intelligent Maintenance Aid (IMA)

Technological complexities of current ground combat systems require advanced maintenance methods to keep the fleet in a state of operational readiness. Currently, maintenance personnel use paper Technical Manuals (TM) that are cumbersome and not easily transportable or updated in the field. This thesis proposes using the latest technology to support maintainers in the field or depot by integrating the TMs with the onboard diagnostics Built-In-Test (BIT) and Fault Isolation Test (FIT) of the vehicle, to provide the maintainer with an improved diagnostics tool to expedite troubleshooting analysis. This will be accomplished by connecting the vehicle, using the vehicle's 1553 multiplex bus, with the Graphical User Interface (GUI) of an Intelligent Maintenance Aid (IMA). The IMA will use Troubleshooting Procedure (TP) codes generated during BIT and FIT testing. Using the information provided by these TP codes, through the IMA GUI, information from the technical manuals will be displayed to aid the maintainers in their diagnostic work. The results of this thesis will serve as a baseline for further research and will be presented to the program management office for combat systems (PM-CS) for further consideration and development.http://archive.org/details/intelligentmaint109452719US Army RDECOM-TACOM author (civilian).Approved for public release; distribution is unlimited

Evolution of maintenance strategies in oil and gas industries: the present achievements and future trends

Engineering Systems maintenance and reliability challenges have drawn serious attention of researchers and industrialists all over the world due to continuous evolution, innovation and complexity of modern technologies deployed in manufacturing and production systems. These systems need very high reliability and availability due to business, mission and safety critical nature of their operations. This paper reviews evolution of systems or equipment maintenance strategies practiced over the years in complex industrial and manufacturing systems such as oil and gas production systems, satellite communication system, spacecraft navigational system, nuclear power plants, etc. The paper also examines the current maintenance and reliability philosophies, their limitations and highlights major breakthroughs and achievements with regards to complex engineering systems maintenance. Intelligent maintenance, a novel approach to complex engineering systems maintenance and reliability sustainment is proposed. The proposed approach reintegrates operation and maintenance phase into system development life cycle, adopts advanced engineering tools and methodology in developing condition-based predictive maintenance, an intelligent maintenance system with resilient, autonomous and adaptive capabilities. Application of Neural network approach to multisensor data fusion for condition-based predictive maintenance system is briefly presented

Maintenance Knowledge Management with Fusion of CMMS and CM

Abstract- Maintenance can be considered as an information, knowledge processing and management system. The management of knowledge resources in maintenance is a relatively new issue compared to Computerized Maintenance Management Systems (CMMS) and Condition Monitoring (CM) approaches and systems. Information Communication technologies (ICT) systems including CMMS, CM and enterprise administrative systems amongst others are effective in supplying data and in some cases information. In order to be effective the availability of high-quality knowledge, skills and expertise are needed for effective analysis and decision-making based on the supplied information and data. Information and data are not by themselves enough, knowledge, experience and skills are the key factors when maximizing the usability of the collected data and information. Thus, effective knowledge management (KM) is growing in importance, especially in advanced processes and management of advanced and expensive assets. Therefore efforts to successfully integrate maintenance knowledge management processes with accurate information from CMMSs and CM systems will be vital due to the increasing complexities of the overall systems. Low maintenance effectiveness costs money and resources since normal and stable production cannot be upheld and maintained over time, lowered maintenance effectiveness can have a substantial impact on the organizations ability to obtain stable flows of income and control costs in the overall process. Ineffective maintenance is often dependent on faulty decisions, mistakes due to lack of experience and lack of functional systems for effective information exchange [10]. Thus, access to knowledge, experience and skills resources in combination with functional collaboration structures can be regarded as vital components for a high maintenance effectiveness solution. Maintenance effectiveness depends in part on the quality, timeliness, accuracy and completeness of information related to machine degradation state, based on which decisions are made. Maintenance effectiveness, to a large extent, also depends on the quality of the knowledge of the managers and maintenance operators and the effectiveness of the internal & external collaborative environments. With emergence of intelligent sensors to measure and monitor the health state of the component and gradual implementation of ICT) in organizations, the conceptualization and implementation of E-Maintenance is turning into a reality. Unfortunately, even though knowledge management aspects are important in maintenance, the integration of KM aspects has still to find its place in E-Maintenance and in the overall information flows of larger-scale maintenance solutions. Nowadays, two main systems are implemented in most maintenance departments: Firstly, Computer Maintenance Management Systems (CMMS), the core of traditional maintenance record-keeping practices that often facilitate the usage of textual descriptions of faults and actions performed on an asset. Secondly, condition monitoring systems (CMS). Recently developed (CMS) are capable of directly monitoring asset components parameters; however, attempts to link observed CMMS events to CM sensor measurements have been limited in their approach and scalability. In this article we present one approach for addressing this challenge. We argue that understanding the requirements and constraints in conjunction - from maintenance, knowledge management and ICT perspectives - is necessary. We identify the issues that need be addressed for achieving successful integration of such disparate data types and processes (also integrating knowledge management into the “data types” and processes)

Precise vehicle location as a fundamental parameter for intelligent selfaware rail-track maintenance systems

The rail industry in the UK is undergoing substantial changes in response to a modernisation vision for 2040. Development and implementation of these will lead to a highly automated and safe railway. Real-time regulation of traffic will optimise the performance of the network, with trains running in succession within an adjacent movable safety zone. Critically, maintenance will use intelligent trainborne and track-based systems. These will provide accurate and timely information for condition based intervention at precise track locations, reducing possession downtime and minimising the presence of workers in operating railways. Clearly, precise knowledge of trains’ real-time location is of paramount importance. The positional accuracy demand of the future railway is less than 2m. A critical consideration of this requirement is the capability to resolve train occupancy in adjacent tracks, with the highest degree of confidence. A finer resolution is required for locating faults such as damage or missing parts, precisely. Location of trains currently relies on track signalling technology. However, these systems mostly provide an indication of the presence of trains within discrete track sections. The standard Global Navigation Satellite Systems (GNSS), cannot precisely and reliably resolve location as required either. Within the context of the needs of the future railway, state of the art location technologies and systems were reviewed and critiqued. It was found that no current technology is able to resolve location as required. Uncertainty is a significant factor. A new integrated approach employing complimentary technologies and more efficient data fusion process, can potentially offer a more accurate and robust solution. Data fusion architectures enabling intelligent self-aware rail-track maintenance systems are proposed

Intelligent maintenance management in a reconfigurable manufacturing environment using multi-agent systems

Thesis (M. Tech.) -- Central University of Technology, Free State, 2010Traditional corrective maintenance is both costly and ineffective. In some situations it is more cost effective to replace a device than to maintain it; however it is far more likely that the cost of the device far outweighs the cost of performing routine maintenance. These device related costs coupled with the profit loss due to reduced production levels, makes this reactive maintenance approach unacceptably inefficient in many situations. Blind predictive maintenance without considering the actual physical state of the hardware is an improvement, but is still far from ideal. Simply maintaining devices on a schedule without taking into account the operational hours and workload can be a costly mistake. The inefficiencies associated with these approaches have contributed to the development of proactive maintenance strategies. These approaches take the device health state into account. For this reason, proactive maintenance strategies are inherently more efficient compared to the aforementioned traditional approaches. Predicting the health degradation of devices allows for easier anticipation of the required maintenance resources and costs. Maintenance can also be scheduled to accommodate production needs. This work represents the design and simulation of an intelligent maintenance management system that incorporates device health prognosis with maintenance schedule generation. The simulation scenario provided prognostic data to be used to schedule devices for maintenance. A production rule engine was provided with a feasible starting schedule. This schedule was then improved and the process was determined by adhering to a set of criteria. Benchmarks were conducted to show the benefit of optimising the starting schedule and the results were presented as proof. Improving on existing maintenance approaches will result in several benefits for an organisation. Eliminating the need to address unexpected failures or perform maintenance prematurely will ensure that the relevant resources are available when they are required. This will in turn reduce the expenditure related to wasted maintenance resources without compromising the health of devices or systems in the organisation