Supporting group maintenance through prognostics-enhanced dynamic dependability prediction

Condition-based maintenance strategies adapt maintenance planning through the integration of online condition monitoring of assets. The accuracy and cost-effectiveness of these strategies can be improved by integrating prognostics predictions and grouping maintenance actions respectively. In complex industrial systems, however, effective condition-based maintenance is intricate. Such systems are comprised of repairable assets which can fail in different ways, with various effects, and typically governed by dynamics which include time-dependent and conditional events. In this context, system reliability prediction is complex and effective maintenance planning is virtually impossible prior to system deployment and hard even in the case of condition-based maintenance. Addressing these issues, this paper presents an online system maintenance method that takes into account the system dynamics. The method employs an online predictive diagnosis algorithm to distinguish between critical and non-critical assets. A prognostics-updated method for predicting the system health is then employed to yield well-informed, more accurate, condition-based suggestions for the maintenance of critical assets and for the group-based reactive repair of non-critical assets. The cost-effectiveness of the approach is discussed in a case study from the power industry

System monitoring and maintenance policies: a review

In the industrial context, the main goal of the maintenance team is to avoid sudden failures that can cause the stoppage of the system with a consequent loss of production. This means that each maintenance action must be performed before the degradation level of a system exceeds a critical threshold beyond which the failure probability becomes high. The increasing importance given to maintenance is shown not only by the great deal of literature on the topic, but also by the interest in transforming this area from a managerial area to a branch of applied mathematics (Operational Research or Statistics). Maintenance is now considered as a subject and much research activity is concerned with its mathematical modeling rather than with the management processes relating to maintenance itself. In [1], Scarf evidences the great importance of the mathematical modeling of maintenance and the correlated strategic support given by the maintenance management information systems. Nevertheless, no model can be built without an exhaustive collection of data. By data, Author means not only specific figures regarding, for example, failure times, but all information related to the process under study. With the recent advent of condition monitoring and the development of appropriate decision models, critical components of a system can be tracked through appropriate variable(s) correlated to their degradation process, logistic support (for example, spares inventory) can be provided, maintenance history can be stored, predetermined maintenance activity can be alarmed and management reports can be produced. The use of condition monitoring techniques reduces the uncertainty operators feel about the current state of the plant. For example, knowledge about the vibration levels of a rotating bearing gives engineers confidence about its operation in the short term. Data acquired by monitoring systems, maintenance histories collected for specific components can be considered fundamental resources for the mathematical modeling of the maintenance activities. This paper is the first part of two [2], presenting the transition from preventive maintenance policy to the predictive one. In particular, the paper presents a brief review of the subject and some critical considerations about the two maintenance policies

Maintenance Strategies to Reduce Downtime Due to Machine Positional Errors

Manufacturing strives to reduce waste and increase Overall Equipment Effectiveness (OEE). When managing machine tool maintenance a manufacturer must apply an appropriate decision technique in order to reveal hidden costs associated with production losses, reduce equipment downtime competently and similarly identify the machines’ performance. Total productive maintenance (TPM) is a maintenance program that involves concepts for maintaining plant and equipment effectively. OEE is a powerful metric of manufacturing performance incorporating measures of the utilisation, yield and efficiency of a given process, machine or manufacturing line. It supports TPM initiatives by accurately tracking progress towards achieving “perfect production.” This paper presents a review of maintenance management methodologies and their application to positional error calibration decision-making. The purpose of this review is to evaluate the contribution of maintenance strategies, in particular TPM, towards improving manufacturing performance, and how they could be applied to reduce downtime due to inaccuracy of the machine. This is to find a balance between predictive calibration, on-machine checking and lost production due to inaccuracy. This work redefines the role of maintenance management techniques and develops a framework to support the process of implementing a predictive calibration program as a prime method to supporting the change of philosophy for machine tool calibration decision making. Keywords—maintenance strategies, down time, OEE, TPM, decision making, predictive calibration

Improvement in performance of corroding concrete structures using health monitoring systems

Predicting future condition and reliability of the deteriorating structures is vital for their effective management. Probabilistic models have been developed to estimate and predict the extent of deterioration in concrete structures but their input parameters are fraught with uncertainties, hence limiting the effective use of the models for long term predictions. On the other hand, continuous innovations in the sensing and measurement technology have lead to the development of monitoring instruments that can provide continuous (or almost continuous) real time information regarding structural performance. Thus, powerful decisionsupport tools may be developed by combining information obtained through structural health monitoring with probabilistic performance prediction models. The potential benefits of improving performance prediction using health monitoring systems and their implications on the management of deterioration prone structures are presented in this paper. A typical structural element of a bridge (eg slab, beam or a cross beam etc) subjected to chloride induced deterioration is considered. It is shown that the confidence in predicted performance can be improved considerably through the use of health monitoring methods and hence, the management activities such as inspections, repair and maintenance etc can be adjusted whilst keeping consistent target performance levels. A comparison of various probabilistic models for the input parameters (eg exposure conditions, threshold chloride concentration etc) indicates that the effects of uncertainty can be minimised through the inservice health monitoring systems

Predictive maintenance policy for a gradually deteriorating system subject to stress

International audienceThis paper deals with a predictive maintenance policy for a continuously deteriorating system subject to stress. We consider a system with two failure mechanisms which are, respectively, due to an excessive deterioration level and a shock. To optimize the maintenance policy of the system, an approach combining statistical process control (SPC) and condition-based maintenance (CBM) is proposed. CBM policy is used to inspect and replace the system according to the observed deterioration level. SPC is used to monitor the stress covariate. In order to assess the performance of the proposed maintenance policy and to minimize the long-run expected maintenance cost per unit of time, a mathematical model for the maintained system cost is derived. Analysis based on numerical results are conducted to highlight the properties of the proposed maintenance policy in respect to the different maintenance parameters

Condition-based maintenance—an extensive literature review

This paper presents an extensive literature review on the field of condition-based maintenance (CBM). The paper encompasses over 4000 contributions, analysed through bibliometric indicators and meta-analysis techniques. The review adopts Factor Analysis as a dimensionality reduction, concerning the metric of the co-citations of the papers. Four main research areas have been identified, able to delineate the research field synthetically, from theoretical foundations of CBM; (i) towards more specific implementation strategies (ii) and then specifically focusing on operational aspects related to (iii) inspection and replacement and (iv) prognosis. The data-driven bibliometric results have been combined with an interpretative research to extract both core and detailed concepts related to CBM. This combined analysis allows a critical reflection on the field and the extraction of potential future research directions

Evaluating maintenance policies by quantitative modeling and analysis

International audienceThe growing importance of maintenance in the evolving industrial scenario and the technological advancements of the recent years have yielded the development of modern maintenance strategies such as the condition-based maintenance (CBM) and the predictive maintenance (PrM). In practice, assessing whether these strategies really improve the maintenance performance becomes a funda-mental issue. In the present work, this is addressed with reference to an example concerning the stochastic crack growth of a generic mechanical component subject to fatigue degradation. It is shown that modeling and analysis provide information useful for setting a maintenance policy