ForeSee is a cluster of six projects, which have received funding from the European Union’s Horizon 2020 research and innovation programme under the FoF-09-2017 call. UPTIME FFT Use Case Predictive maintenance of complex mobile assets Jeroen Versteeg, Senior Consultant, FFT Produktionssysteme Predictive Project
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ForeSee is a cluster of six projects, which have received funding from the European Union’s Horizon 2020 research and innovation programme under the FoF-09-2017 call.
UPTIME FFT Use CasePredictive maintenance of complex mobile assets
To reframe predictive maintenance strategy in a systematic and unified way by exploiting research advances in three main areas:
• Industry 4.0• I4.0 paves the way for extensive use of physical and virtual sensors generating a
multitude of data.
• Big Data Processing• Availability of big data leads to a strong demand for data-driven, real-time systems
incorporating efficient processing technologies in order to get meaningful insights about business performance.
• Proactive Computing• Proactive event-driven computing is referred to the use of event-driven systems for
mitigating future undesired events or for taking advantage of future opportunities.
Jeroen Versteeg – FFT Produktionssysteme
FFT in a nutshell
Turnkey Body Shops
Turnkey Assembly Lines
Production Technology (Jigs & Tools)
Systems & Test Operations
Automation TechnologyMaintenance
Jeroen Versteeg – FFT Produktionssysteme
FFT Use Case: Overview
• FFT is performing the maintenance under contract for a large european aircraft OEM's major aircraft components transportation jigs (in this case also built by FFT)
• Maintenance of these assets is crucial because they have to be highly available, air- and seaworthy, and are subjected to harsh environmental conditions
• There is a high coordination and reporting overhead in subcontracted maintenance projects
Jeroen Versteeg – FFT Produktionssysteme
Main Challenges in the FFT Demonstrator Case
• High effort to ensure operational reliability:
• Airworthiness ensured by extensive Preflight Checks
• High effort for corrective and preventive maintenance
• Unknown asset condition results in inefficient preparation for maintenance activities
• High availability requirements
• Volatile and very short term notification for maintenance time slots
• No Spare Jigs available
• Difficult Identification of mishandling
• No feedback to FFT design team
Jeroen Versteeg – FFT Produktionssysteme
Typical Failure Cases
Jeroen Versteeg – FFT Produktionssysteme
Typical Failures
⚫ Structural failure
⚫ welding seam cracks
⚫ water/ice
⚫ Overloading (user error)
⚫ Collisions
⚫ Corrosion / aging
⚫ Lost parts
Typical Causes
⚫ Dynamic loading (vibrations, shaking)
⚫ Environmental stress
⚫ User error / user care
Jeroen Versteeg – FFT Produktionssysteme
Status Quo of the Maintenance Project (2017)
• Planned Preventive Maintenance (PPM) and Corrective Maintenance only
• High dependency on customer production processes –high flexibility requirements
• High (manual) effort for asset identification, data collection and further processing (error prone Excel-based processes, manual work for KPI calculation)
• Often unknown condition and location of assets
• No Feedback of Maintenance Experience to the FFT Design Team
• In-Situ at Multiple Customer Sites
Jeroen Versteeg – FFT Produktionssysteme
Jeroen Versteeg – FFT Produktionssysteme
KPI and Enablers
Typical KPI
• On Time Delivery• Response Time
• MTTR Mean Time To Repair
• Asset availability
• On Quality Delivery• All Faults identified, documented and
corrected
• Identification of Root Causes
• Improvement Suggestions
• Operational reliability
• On Cost Delivery• 3% costs savings / year
• Flexible process planning and integration
• Any maintenance activity needs to be in-line with processes of the customer
• Maintenance activities driven by customer demands – planning difficult
• Continuous Information Management
• Transparent information availability to stakeholder
• Documentation of all activities
• Acquisition of asset condition
• Continuous Improvement
• Indicate weak processes and propose improvements
• Indicate weak areas(e.g. bottlenecks or sources of damages)
Enablers
Jeroen Versteeg – FFT Produktionssysteme
Jeroen Versteeg – FFT Produktionssysteme
Scope Definition - Requirements
1. Asset (Health) Data evaluation and management platform featuring:
• Data aggregation, post-processing and storage framework offering rule based automatic data
evaluation
• Capability to manage comprehensive maintenance process
• Transparent data access for different stakeholders
• Open interfaces (to enable integration to other (sub) platforms)
2. Physical asset data acquisition platform featuring:
• Capability to input and measure a wide range of physical quantities (implies development of reliable
methods to indirectly measure conditions by intelligent measurement)
• Modularity and Scalability: easy to add quantity (economic) and quality (additional physical quantities)
• Mobility (robust, unattended operation for extended periods, flexible means of data transmission)
• Certifiable for operation in-flight (Beluga transports)
Jeroen Versteeg – FFT Produktionssysteme
Concept Vision
(Semi-mobile)
Hub
Mobile Sensor Module
Mobile Sensor Module
Mobile Sensor Module
Mobile Sensor Module
Mobile Sensor Module
Client Interface
•Operational Team
Client Interface
• Customer
Client Interface
•Design Team
Client Interface
• Planning Team
Evaluate•Rule based
condition assessment
Plan
Do•Perform
mainte-nance based on condition
Report / Document /
KPI
Optimise•optimise
evaluation rules
Aggregate
Private cloud
data storage
Maintenance Management
Platform
Jeroen Versteeg – FFT Produktionssysteme
Hardware Development / Data Acquisition Platform
v1.5
v2.0
v2.5
SENSEnode
SENSEcore
v3.0
Jeroen Versteeg – FFT Produktionssysteme
UPTIME Platform applied to FFT
UPTIME coverage of FFT-specific implementation focus:
UPTIME (Information) Platform
UPTIME_SENSEFFT Use Case /
Deployment
Jeroen Versteeg – FFT Produktionssysteme
Data Acquisition
FFT SENSEnode Factsheet
❑ Size 65x30mm
❑ 2.4 GHz (BLE / WLAN)
❑ Sub-GHz (490-868 MHz) Long Range RF
✓ Range 1-2 km
❑ Sensors
✓ Motion and orientation
✓ Light
✓ Temperature
✓ Humidity
✓ Air pressure
✓ Force / Weight (Strain Gauges via ADCs)
❑ LEDs and LCD display
❑ Battery lifetime (AA cell) up to 1-2 years (sleep mode)
Jeroen Versteeg – FFT Produktionssysteme
UPTIME - Stream Data Analytics
Presenter - Company
Exact location
during the
whole transport
cycle
Outlier forcast for
defined time span
Outlier gauges
Orientation:
compass
direction
Accelearation
e.g. shocks from
road bumps,
wholes, train
tracks, etc. and
outlier detection
Gyroscope:
orientation and
angular velocity
Asset selection
Jeroen Versteeg – FFT Produktionssysteme
UPTIME - Batch Data Analytics
Presenter - Company
Filter selection and
combination Conducted Pre-Load
Checks and entries
per PLC
Gauges for quick
overview of figures
of main concern
Tags associated to
PLC entries based
on list of terms
Selection of fields from
Pre-Load Checks (PLC)
PLC entries according to
check routine conduction
Jeroen Versteeg – FFT Produktionssysteme
UPTIME – Role Based Info Access
Stakeholder / Roles Example
“Fleet overview” with (per-asset) drill-down
functionalities generated from semi-structured
data (maintenance checklists).
Can be used by:
Maintenance Coordinator
⚫ trend analysis
⚫ priority identification
⚫ correlation finding
Engineer
⚫ hot spot identification
⚫ improvement effectivenes
Owner / Operator
⚫ Overview / trend analysis / reporting
Jeroen Versteeg – FFT Produktionssysteme
ROI Projection (Example, “MaaS”)
Recall the main points of focus:
1) Maintenance Planning
2) Maintenance Execution
3) Reporting
4) (Continuous) Improvement
⚫ (Product + Process)
That was the return, so what about the investment?
Difficult to say (UPTIME doesn’t yet have a “price tag”), but let’s
consider effort for training and deployment, and assert that we
could be break even after approx. 1-1.5 years for projects with up
to ~15 p. permanent maintenance team.
(And better beyond that size!)
FFT’s Use Case “Special” Features:◆ “MaaS” (“Maintenance-as-a-Service”)
◆ Mobile and diverse assets, dynamic scope (“fleet” of assets)
◆ Additional layer(s) of “End User” type stakeholders
Jeroen Versteeg – FFT Produktionssysteme
End User Assessment / Feedback
• Ergonomics/ease of use
⚫ Platform: intuitive web interface, puts useful asset data “at your fingertips”
⚫ Platform: the configurability/customisation within the platform (or a clearer indication which types of customisations are enabled and how) could still be improved. (Normal for the current state of the project).