mdh.sePublications
Change search
CiteExportLink to record
Permanent link

Direct link
Cite
Citation style
  • apa
  • ieee
  • modern-language-association-8th-edition
  • vancouver
  • Other style
More styles
Language
  • de-DE
  • en-GB
  • en-US
  • fi-FI
  • nn-NO
  • nn-NB
  • sv-SE
  • Other locale
More languages
Output format
  • html
  • text
  • asciidoc
  • rtf
Implementation of Condition Based Maintenance in Manufacturing Industry – A Pilot Case Study
Volvo GTO, Köping, Sweden . (Innofacture)ORCID iD: 0000-0001-8729-2955
Mälardalen University, School of Innovation, Design and Engineering, Innovation and Product Realisation.ORCID iD: 0000-0002-0729-0122
2014 (English)In: 2014 IEEE Conference on Prognostics and Health Management (PHM), IEEE conference proceedings, 2014, p. Article number 7036377-Conference paper, Published paper (Refereed)
Abstract [en]

This paper presents a guide for implementation of Condition Based Maintenance (CBM) in a manufacturing industry, considering the technical constituents and organizational aspects when implementing CBM. The empirical base for the study is a case study from a major manufacturing site in Sweden. The data was collected during a pilot project to implement CBM at the case company. The purpose of the pilot study at the company was to implement online condition monitoring on some of the critical components in the hardening process. Hereby, two of the main online condition monitoring techniques namely vibration analysis and Shock Pulse Method (SPM) have been implemented and tested on electric motors to monitor bearing conditions. The paper presents the process of implementation and the elements included in this process. Some of the main elements in the implementation process are selection of the components to be monitored, techniques and technologies as well as installation of the technologies and finally how to analyze the results from the condition monitoring. The data from online condition monitoring on the electric motors, driving the furnace fans, are recorded and presented in the paper including breakdown data on two objects. This information is leading to useful and reliable knowledge for maintenance work to be cost effective and be able to increase the overall equipment availability (OEA). In addition to this, the result indicates to what extent advanced CBM practices are applicable in the hardening environment in the manufacturing company and it provides guidance for further research and development in this area. The paper concludes with a discussion on possible future trends and research areas, needed to increase the effective and efficient use of CBM.

Place, publisher, year, edition, pages
IEEE conference proceedings, 2014. p. Article number 7036377-
Keywords [en]
Condition based maintenance, Condition monitoring, Implementation
National Category
Reliability and Maintenance
Identifiers
URN: urn:nbn:se:mdh:diva-28480DOI: 10.1109/ICPHM.2014.7036377Scopus ID: 2-s2.0-84929587482ISBN: 9781479949427 (print)OAI: oai:DiVA.org:mdh-28480DiVA, id: diva2:826048
Conference
2014 IEEE Conference on Prognostics and Health Management (PHM), 22-25 June, Cheney, USA
Funder
XPRES - Initiative for excellence in production researchAvailable from: 2015-06-24 Created: 2015-06-24 Last updated: 2017-10-23Bibliographically approved
In thesis
1. Strategic Maintenance Development focusing on use of Condition Based Maintenance in Manufacturing Industry
Open this publication in new window or tab >>Strategic Maintenance Development focusing on use of Condition Based Maintenance in Manufacturing Industry
2015 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

The growth of global competition caused remarkable changes in the way manufacturing companies operate. These changes have affected maintenance and made its role even more crucial in business success. In order to stay competitive, manufacturing companies need to continuously increase the effectiveness and efficiency of their production processes. Further, by introducing lean manufacturing the concern about equipment availability is increased and so, the demand for effective maintenance. Despite the increasing demand on reliable production equipment, few manufacturing companies work with strategic maintenance development. Moreover, conventional maintenance strategies such as corrective maintenance are not sufficient today to fulfill the industrial needs on maximum reduction of failures and degradations of manufacturing systems. The concept of maintenance has evolved over the last few decades from a corrective attitude (maintenance intervention after a failure), to a predictive attitude (maintenance intervention fixed to prevent the fault). Strategies and concepts such as Condition Based Maintenance (CBM) have thus evolved to support this ideal situation. CBM is a set of maintenance actions based on real-time or near real-time assessment of equipment condition, which is obtained from embedded sensors and/or external tests and measurements taken by portable equipment and/or subjective condition monitoring. CBM is becoming recognized as the most efficient strategy for carrying out maintenance in a wide variety of industries. However, the practical implementation of advanced maintenance technologies, such as CBM, in manufacturing industry is more scarce.

Therefore, the objective with this research is to study on how to implement and develop an effective and efficient CBM strategy in manufacturing industry. This thesis will start with an analysis of the overall maintenance management to illustrate how to formulate a maintenance strategy, following with the focus on CBM; cost effectiveness of implementing CBM; an introductory review of applied CBM practices and CBM implementation process, all in manufacturing industry. The data was collected through case studies mainly at one major manufacturing site. The main part of the data was collected during a pilot project to implement CBM. As the result, a formulated maintenance strategy has been developed and presented. Factors to evaluate CBM cost effectiveness have been assessed. These factors indicate the benefits of CBM mostly in reducing probability of having maximal damage in production equipment and reducing production losses particularly in high production volumes. Further, a process of CBM implementation has been presented. Some of the main elements in the process are selection of the components to be monitored, techniques and technologies as well as installation of the technologies and finally how to analyze the results from the condition monitoring.

Place, publisher, year, edition, pages
Västerås: Mälardalen University, 2015
Series
Mälardalen University Press Licentiate Theses, ISSN 1651-9256 ; 213
National Category
Reliability and Maintenance
Research subject
Innovation and Design
Identifiers
urn:nbn:se:mdh:diva-28486 (URN)978-91-7485-220-2 (ISBN)
Presentation
2015-09-24, Filen, Smedjegatan 37, Eskilstuna, 10:00 (English)
Opponent
Supervisors
Available from: 2015-06-25 Created: 2015-06-24 Last updated: 2017-10-23Bibliographically approved
2. Condition Based Maintenance in the Manufacturing Industry: From Strategy to Implementation
Open this publication in new window or tab >>Condition Based Maintenance in the Manufacturing Industry: From Strategy to Implementation
2017 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

The growth of global competition has led to remarkable changes in the way manufacturing companies operate. These changes have affected maintenance and made its role even more crucial for business success. To remain competitive, manufacturing companies must continuously increase the effectiveness and efficiency of their production processes. Furthermore, the introduction of lean manufacturing has increased concerns regarding equipment availability and, therefore, the demand for effective maintenance. That maintenance is becoming more important for the manufacturing industry is evident in current discussions on national industrialization agendas. Digitalization, the industrial internet of things (IoT) and their connections to sustainable production are identified as key enablers for increasing the number of jobs in industry. Agendas such as “Industry 4.0” in Germany and “Smart Industry” in Sweden are promoting the connection of physical items such as sensors, devices and enterprise assets, both to each other and to the internet. Machines, systems, manufactured parts and humans will be closely interlinked to collaborative actions. Every physical object will formulate a cyber-physical system (CPS), and it will constantly be linked to its digital fingerprint and to intensive connection with the surrounding CPSs of its on-going processes.

That said, despite the increasing demand for reliable production equipment, few manufacturing companies pursue the development of strategic maintenance. Moreover, traditional maintenance strategies, such as corrective maintenance, are no longer sufficient to satisfy industrial needs, such as reducing failures and degradations of manufacturing systems to the greatest possible extent. The concept of maintenance has evolved over the last few decades from a corrective approach (maintenance actions after a failure) to a preventive approach (maintenance actions to prevent the failure). Strategies and concepts such as condition based maintenance (CBM) have thus evolved to support this ideal outcome. CBM is a set of maintenance actions based on the real-time or near real-time assessment of equipment conditions, which is obtained from embedded sensors and/or external tests and measurements, taken by portable equipment and/or subjective condition monitoring. CBM is increasingly recognized as the most efficient strategy for performing maintenance in a wide variety of industries. However, the practical implementation of advanced maintenance technologies, such as CBM, is relatively limited in the manufacturing industry.

Based on the discussion above, the objective of this research is to provide frameworks and guidelines to support the development and implementation of condition based maintenance in manufacturing companies.  This thesis will begin with an overall analysis of maintenance management to identify factors needed to strategically manage production maintenance. It will continue with a focus on CBM to illustrate how CBM could be valued in manufacturing companies and what the influencing factors to implement CBM are. The data were collected through case studies, mainly at one major automotive manufacturing site in Sweden. The bulk of the data was collected during a pilot CBM implementation project. Following the findings from these efforts, a formulated maintenance strategy is developed and presented, and factors to evaluate CBM cost effectiveness are assessed. These factors indicate the benefits of CBM, mostly with regard to reducing the probability of experiencing maximal damage to production equipment and reducing production losses, particularly at high production volumes. Furthermore, a process of CBM implementation is presented. Some of the main elements in the process are the selection of the components to be monitored, the techniques and technologies for condition monitoring and their installation and, finally, the analysis of the results of condition monitoring. Furthermore, CBM of machine tools is presented and discussed in this thesis, focusing on the use of vibration monitoring technique to monitor the condition of machine tool spindle units.

Place, publisher, year, edition, pages
Eskilstuna: Mälardalen University, 2017
Series
Mälardalen University Press Dissertations, ISSN 1651-4238 ; 242
Keywords
Condition based maintenance; Condition monitoring; Manufacturing industry
National Category
Reliability and Maintenance
Research subject
Innovation and Design
Identifiers
urn:nbn:se:mdh:diva-37130 (URN)978-91-7485-355-1 (ISBN)
Public defence
2017-12-01, Raspen, Mälardalens högskola, Eskilstuna, 10:00
Opponent
Supervisors
Projects
INNOFACTURE - innovative manufacturing development
Available from: 2017-10-23 Created: 2017-10-23 Last updated: 2017-11-17Bibliographically approved

Open Access in DiVA

No full text in DiVA

Other links

Publisher's full textScopus

Authority records BETA

Bengtsson, Marcus

Search in DiVA

By author/editor
Rastegari, AliBengtsson, Marcus
By organisation
Innovation and Product Realisation
Reliability and Maintenance

Search outside of DiVA

GoogleGoogle Scholar

doi
isbn
urn-nbn

Altmetric score

doi
isbn
urn-nbn
Total: 114 hits
CiteExportLink to record
Permanent link

Direct link
Cite
Citation style
  • apa
  • ieee
  • modern-language-association-8th-edition
  • vancouver
  • Other style
More styles
Language
  • de-DE
  • en-GB
  • en-US
  • fi-FI
  • nn-NO
  • nn-NB
  • sv-SE
  • Other locale
More languages
Output format
  • html
  • text
  • asciidoc
  • rtf