Digitalization in maintenance Phillip Tretten Luleå University of Technology LULEÅ-SWEDEN
Maintenance today
Scheduled maintenance Maintenance stops Planned maintenance actions Hours/days/years/
Corrective maintenance Maintenance personnel Operator maintenance
Preventive maintenance Maintenance personnel Operator maintenance
Present trends
Condition Monitoring More and better measurements Commercial services SKF In-house solutions Regulated requirements
Measurement of critical components
Measurement of critical components Trafikverket - Sunderbyn
Smarter maintenance Operators and maintenance personnel should work together
Condition Based Maintenance
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
Online monitoring SKF condition monitoring Online wireless monitoring of components
Real-time monitoring of all systems OSIpi system connects all databases Real-time analysis Big Data Produce work-orders Send warnings Communication
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?
Prognostics Prognostic sensors Analysis methods Prognostic analysis Decision making
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
Visualization and Decision Support
Maintenance challenges System Human
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
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?
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
Aircraft manuals Several manuals needed for one action Paper Confusion occurs
Aircraft technician online
Mobile solutions
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
Measurement of critical components
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?
Project Phases Needs Ideas Prototypes
Checklist/ Rounds Before QuickTag Paper lists Not following SOO Incomplete reports Poor follow-up
Diary Dokument Checklist Instruktions History PROTOTYPE: QuickTag Everything in one App Increased Availability Increased Efficiency
Example: Control and failure report (WO) Tag telephone Chose Failure report Describe problem Choose Finished
Today: Boliden Aitik QuickTag being used daily Operators Temporary workers Maintenance El/Mech Preventive Maintenance
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
Further development - Aitik Direkt access to more systems Reporting of mishaps, risks and other problems Better feedback to the operators
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
Microsoft Hololens BMW DAQRI smart helmet Augmented Reality
XM Reality
Future maintenance solutions Robotics Maintenance Robots Autonomous maintenance robots Humans & robots - cooperating simultaneously
Student work Course work Project course Part-time work Summer job
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
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
Thank you! Phillip Tretten, PhD Luleå University of Technology