Digitalization in maintenance. Phillip Tretten Luleå University of Technology LULEÅ-SWEDEN

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1 Digitalization in maintenance Phillip Tretten Luleå University of Technology LULEÅ-SWEDEN

2 Maintenance today

3 Scheduled maintenance Maintenance stops Planned maintenance actions Hours/days/years/

4 Corrective maintenance Maintenance personnel Operator maintenance

5 Preventive maintenance Maintenance personnel Operator maintenance

6 Present trends

7 Condition Monitoring More and better measurements Commercial services SKF In-house solutions Regulated requirements

8 Measurement of critical components

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10 Measurement of critical components Trafikverket - Sunderbyn

11 Smarter maintenance Operators and maintenance personnel should work together

12 Condition Based Maintenance

13 Systems communicate Production and Maintenance systems communicate to each other Online monitoring of systems Automatically generated work orders based upon degradations in the system Predefined thresholds Self-learning systems that refine thresholds

14 Online monitoring SKF condition monitoring Online wireless monitoring of components

15 Real-time monitoring of all systems OSIpi system connects all databases Real-time analysis Big Data Produce work-orders Send warnings Communication

16 Maintenance Prognostics Predicting the time a system/component will no longer perform its intended function Prediction of Remaining Useful Life = Prognostics Who does it today?

17 Prognostics Prognostic sensors Analysis methods Prognostic analysis Decision making

18 Context-aware & CBM based Decision Support Solutions for maintenance actions Information models Knowledge models Context models Maintenance Data Data Fusion & Integration Big Data Modelling & Analysis Context sensing & adaptation

19 Visualization and Decision Support

20 Maintenance challenges System Human

21 System challenges Incompatible systems Proprietary systems No such thing as an all in one solution Individual needs for each system the right information, to the right person, at the right time

22 Human challenges Is maintenance conducted correctly? Is it conducted at the right time? Is it reported correctly? Personal ownership of the equipment? What does the organization promote? Only production is prioritized? Does production and maintenance cooperate? Who wins?

23 Human Error Where does the problem come from? The operator/technician who makes mistakes The equipment that no one understands The organization that promotes mistakes

24 Aircraft manuals Several manuals needed for one action Paper Confusion occurs

25 Aircraft technician online

26 Mobile solutions

27 QuickTag A mobile solution that supports daily rounds Camilla Grane, Dr. Teknisk psykologi, Luleå tekniska universitet Samuel Jonsson, Anrikningschef, Boliden Aitik Kjell-Arne Johansson, Kvarntekniker, Boliden Aitik Erika Johansson, Processoperatör, Skyddsombud, Boliden Aitik

28 Measurement of critical components

29 QuickTag A mobile application for ease of use and Implemented - Boliden Aitik 2016 ca 60 people use it daily Why QuickTag? How does QuickTag work? Is QuickTag useful? What does Boliden say?

30 Project Phases Needs Ideas Prototypes

31 Checklist/ Rounds Before QuickTag Paper lists Not following SOO Incomplete reports Poor follow-up

32 Diary Dokument Checklist Instruktions History PROTOTYPE: QuickTag Everything in one App Increased Availability Increased Efficiency

33 Example: Control and failure report (WO) Tag telephone Chose Failure report Describe problem Choose Finished

34 Today: Boliden Aitik QuickTag being used daily Operators Temporary workers Maintenance El/Mech Preventive Maintenance

35 QuickTag: Results Increased control Kontroll utförd: Var, När, Vem Vissa kontroller är lagstandard Simplifed planning Bilder säger mer än ord Direkt kopplade till rätt objekt Improved failure reports (WO) Skrivs på rätt objektsnummer Återkommande fel har standardbeskrivning Reduced risk for failures Tydliga beskrivningar hjälper oerfarna operatörer. Simplify operator taskas Ger åtkomst till information och rapporteringsfunktioner direkt på plats

36 Further development - Aitik Direkt access to more systems Reporting of mishaps, risks and other problems Better feedback to the operators

37 Total cost: Grundapplikation Integrering med befintliga system Mobiltelefoner (användes redan i Aitik) Arbetsordrar (Maximo) Dagbok Dokument, tex ritningar Vidareutveckling Geo-fence för taggning utomhu Offline-stöd Ronderingsöversikt (statistik) Uppdatering av ronderingsmallar och arbetsinstruktioner Intern Boliden App-store Taggning Sätta upp skyltar NFC-taggar Utbildning Total kostnad: ~1,5 miljoner kr

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39 Microsoft Hololens BMW DAQRI smart helmet Augmented Reality

40 XM Reality

41 Future maintenance solutions Robotics Maintenance Robots Autonomous maintenance robots Humans & robots - cooperating simultaneously

42 Student work Course work Project course Part-time work Summer job

43 Project course Maintenance Engineering Kartläggning av företaget Bolidens underhållsarbete i Maximo Tillförlitlighetsanalyser i Boliden - vilken data krävs för bättre uppföljning Nulägesanalys av infrakten vid Bolidens anrikningsverk Kritikalitetsklassificering hos Smurfit Kappa Piteå Valsunderhåll dokumentation rapporter och rutiner Användningsfallmodellering av Underhållssystem

44 Thesis work Avvikelser vid underhåll av JAS 39 Gripen Analysis and study of reliability CMMS Benchmarking Development In Mining Industries Tillståndsövervakning av järnvägsinfrastruktur Beräkning av OEE för en produktionslinje Förbättrad provtagning för säkrare analyser Driftoperatörernas tillståndskontroller på LKAB CM using Thermography Lagerkostnad för reservdelar

45 Thank you! Phillip Tretten, PhD Luleå University of Technology