Through-life Engineering Services

Name: Through-life Engineering Services | Motivation, Theory, and Practice
Brand: Springer
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Motivation, Theory, and Practice

Louis Redding Rajkumar Roy(Herausgeber*in)

Springer (Verlag)

Erschienen am 26. Dezember 2014

XVI, 457 Seiten

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978-3-319-12111-6 (ISBN)

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Inhalt

Intro
Some Food for Thought!
Foreword
Preface
Acknowledgments
Contents
1 Introduction
Abstract
1.1 Background and Rationale for This Book
1.2 Derivation of the Book Structure
References
Part I Introduction to Through-lifeEngineering Services
2 Through-Life Engineering Services: Definition and Scope: A Perspective from the Literature
Abstract
2.1 Introduction to, and Definition of, Through-Life Engineering Services (TES)
2.1.1 Evolution of Maintenance in Support of Manufactured Products
2.2 Through-Life Engineering Services---a Definition
2.3 The Scope of Through-Life Engineering Services
2.3.1 Knowledge of Use
2.3.2 Knowledge of Diagnostics and Prognostics Aligned to Degradation Mechanisms
2.3.3 Knowledge of Failure Modes and Degradation Mechanisms
2.3.4 Knowledge of Means of Repair (Restore Design Function)
2.3.5 Knowledge of Design and Manufacturing
2.3.6 Knowledge of Systems
2.3.7 The Role of Standards, Procedures, and Codes of Practice in TES
2.4 Conclusion
References
3 Through-Life Engineering Services: The NedTrain Case
Abstract
3.1 Introduction
3.2 The Company
3.2.1 High Costs of Rolling Stock
3.2.2 Fleet Development
3.3 Design of New Trains
3.3.1 System Integrator and Maintenance Integrator
3.3.2 New Sprinter Light Train
3.4 Operational Processes in Order (2005--2010)
3.5 Technical Management Close to the Workshop Floor (2010--2015)
3.5.1 Continuous Improvement of Fleet Performance
3.6 Clear Information Provision: A Fundamental Prerequisite (2013--2015)
3.7 Rolling Stock Management (2013--2015)
3.8 Maintenance Closer to Operations (2015--2020)
3.8.1 Real Time Monitoring Enabling Dynamic Maintenance Scheduling
3.9 Life Cycle Logistics R&D Program
3.10 Investing in People
3.11 Summary
Acknowledgments
References
Part II Data, Diagnostics and Prognostics
4 The Impact of No Fault Found (NFF) on Through Life Engineering Services
Abstract
4.1 Introduction
4.2 No-Fault-Found (NFF) Taxonomy
4.3 Understanding NFF
4.4 The Consequence of NFF
4.5 Common Causes and Impact of NFF
4.6 General Causes
4.6.1 Organisational and Culture
4.6.2 Procedures and Rules
4.6.3 Operational Pressure
4.6.4 Technical Inefficiencies
4.6.5 Workforce Behaviours
4.7 Additional Subject Areas that Contribute to NFF
4.7.1 Training
4.7.2 Communication and Miscommunication
4.7.3 Lack of Historical Data
4.7.4 Supply Chain Effect
4.8 Technical Causes
4.8.1 Undefined or Inappropriate Performance Measures
4.8.2 BIT/BITE and Testing
4.8.3 Erroneous Repairs
4.8.4 Information on Usage and Operating Environment
4.8.5 Inadequate Design
4.8.6 Interactions Between Software in Integrated Systems
4.8.7 New Technology Adoption
4.9 Cost
4.9.1 First Level of Support
4.9.2 At the Second and Subsequent Levels of Support
4.9.3 In the Supply Chain
4.10 Diagnostic Success
4.11 Mitigation of NFF
4.12 Conclusion
References
5 Holistic Prognostics
Abstract
5.1 Definitions
5.1.1 The Full Range of Prognostics
5.1.2 Prognostics Type 1: Reliability Statistics
5.1.3 Prognostics Type 2---Environmental Factors
5.1.4 Prognostics Type 3---Individual Machine Effects
5.1.5 Measuring Failure Mechanisms or Direct Effects
5.1.6 A Proposed Extension to the Prognostics Model
5.1.7 Metrics for Prognostics
5.1.8 The Problems with Validation and Prognostic `Ground Truth'
5.1.9 Possible Solutions to Lack of Failure Data for Validation
5.2 Conclusion
References
6 Ultra Low Carbon Vehicle Management Based on Telematic Monitoring
Abstract
6.1 Introduction
6.2 Technical Aspects of Telemetry Systems
6.2.1 Telemetry System Functionality
6.2.2 Technological Enablers
6.3 Operational and Organisational Drivers for the Use of Telemetry Systems
6.4 Barriers to Increased Use of Telematics
6.4.1 On-Board Systems
6.4.2 Data Processing Considerations
6.4.3 Privacy Concerns
6.5 ULCV Specific Applications of Telematics
6.5.1 Management of Charge and Range
6.5.2 Telematic Condition Monitoring
6.6 Wider Benefits of Telematic Monitoring
6.6.1 Smart Traffic Management
6.6.2 Removing Road Signs
6.6.3 The Development of Autonomous Vehicle Technology
6.7 Conclusions
References
7 A Weak Signal Detection Method Based on Stochastic Resonances and Its Application to the Fault Diagnosis of Critical Mechanical Components
Abstract
7.1 Introduction
7.2 Fundamental of SR and Normalized Scale Transform
7.2.1 Fundamental of SR
7.2.2 Normalized Scale Transform of SR Model
7.2.3 Averaged SR Model with Normalized Scale Transform
7.2.4 Model Validation Using Simulated Data
7.3 SR Model by Adding a Harmonic Excitation
7.3.1 SR Interpretation via Melnikov Theory and Chaotic Dynamic Approach
7.3.2 Simulation for Enhancing the Detection of Weak Signal by Adding a Harmonic Excitation
7.3.2.1 Detecting Weak Signal at Low Frequency
7.3.2.2 Detecting Weak Signal with Arbitrary Frequency
7.4 Validation Using Experimental Data
7.4.1 Envelop Analysis
7.4.2 SR Output of Driven by Envelope Signal
7.4.3 Weak Characteristic Signal Detection by SR of Adding a Harmonic Excitation
7.5 Conclusion
Acknowledgments
References
Part III Component Degradationand Design
8 Active Thermography in Through-Life Engineering
Abstract
8.1 Introduction
8.2 Motivation
8.3 Thermography
8.3.1 Passive Thermography
8.3.2 Active Thermography
8.3.3 Pulsed Thermography
8.3.4 Lock-in Thermography
8.4 Pulsed Thermography---Case Study
8.5 Automation of Thermographic NDT
8.5.1 Data Capture Stage
8.5.2 Data Processing and Analysis Stage
8.6 Summary
References
9 Maintenance, Repair and Overhaul in Through-Life Engineering Services
Abstract
9.1 Introduction on MRO
9.2 Fraunhofer Innovation Cluster MRO
9.2.1 Condition Monitoring and Diagnosis
9.2.1.1 Data Mining and Visualization of Diagnostic Messages for Condition Monitoring
Approach for Data Mining
Data Mining with Graphical User Interface (GUI)
9.2.2 MRO Planning and Digital Assistance
9.2.2.1 Computer Vision Analysis of 3D Scanned Circuit Boards for Functional Testing and Redesign
Printed Circuit Boards Specific 3D Digitization
Recognition of Printed Circuit Boards Parts
Segmentation of Pins and Printed Circuit Board Tracks
9.2.3 Cleaning
9.2.3.1 Development of a Miniaturised Cleaning Nozzle for Dry Ice Blasting
9.2.4 Repair and Overhaul Technologies
9.2.4.1 Repair Cell for Engine and Turbine Components
Concept of a Robot-based Repair Tool Kit
Process Chain
Adaptive Robot-guided Grinding and Polishing
Determining Technological Parameters for the Used Abrasive Belts
Conclusion
9.2.4.2 Design of Experiments for Laser Metal Deposition in Maintenance, Repair and Overhaul Applications
Materials and Experimental Procedure
Effects on Bead Width and Height
Summary and Outlook
9.3 Outlook to MRO in the Future
Acknowledgments
References
10 Modeling and Sequential Repairs of Systems Considering Aging and Repair Effects
Abstract
10.1 Introduction
10.2 A Modified Proportional Failure Intensity Model
10.3 Statistical Inference and Approximation
10.3.1 Maximum Likelihood Estimates
10.3.2 Tests for Aging and Repair Effects
10.3.3 Fisher Information Matrix
10.3.4 Approximation and Confidence Bounds for m(t) and lambda (t)
10.4 Application to Sequential Repair/Replacement Decision-Making
10.4.1 Mathematical Formulation
10.4.2 Distribution of Short-Run Cost Rate
10.5 Numerical Examples
10.5.1 Aircraft Air-Conditioning Equipment Data
10.5.2 Hydraulic Systems Data
10.6 Conclusion
A.1. Appendix 1: Proof of Theorem 1
A.2. Appendix 2: Proof of Theorem 2
A.3. Appendix 3: Proof of Theorem 3
References
11 Cold Spray Coating Technology for Metallic Components Repairing
Abstract
11.1 Introduction
11.2 Basic Features and Equipment
11.3 Physical and Mechanical Properties
11.4 Applications
11.5 Conclusions
References
Part IV System Degradationand Design in TES
12 Through-Lifecycle Aspects for Functional Products to Consider During Development and Operation: A Literature Review
Abstract
12.1 Introduction
12.2 Research Approach
12.3 Literature Review---Existing and Potential New Through-Lifecycle Aspects for Functional Products
12.4 Discussion and Conclusions
Acknowledgments
References
13 Understanding Maintenance Decisions: How to Support Acquisition of Capital Assets
Abstract
13.1 Introduction
13.2 Methodology
13.3 Results of Literature Review
13.3.1 Strategic, Tactical and Operational Decisions
13.3.2 Strategic Maintenance Decisions
13.4 Results of Case Research
13.4.1 New Approach to Planning Maintenance During Acquisition
13.4.2 Strategic, Tactical and Operational Decisions
13.4.3 Strategic Decisions
13.5 Discussion
13.6 Conclusions
Acknowledgments
References
14 Integration of Operational Data into Maintenance Planning
Abstract
14.1 Introduction
14.2 State of the Art
14.2.1 Life Expectancy Models
14.2.2 Proportional Hazards Model
14.2.3 Kalman Filter
14.2.4 Hidden Markov Models
14.3 Applications
14.4 State of the Art Assessment
14.5 Approach
14.6 Data Processing
14.7 Weibull PHM
14.7.1 Cost Minimal Replacement
14.7.2 Application
14.8 Summary
Acknowledgments
References
15 Integrated Maintenance System Trend and a Maintenance Scheduling System Application
Abstract
15.1 Introduction
15.2 Reviews of Previous Studies
15.2.1 Changes of Maintenance Methods
15.2.2 Optimization of Operation and Maintenance
15.2.3 Proactive Maintenance for Re-entrant Flow Manufacturing
15.3 A New Proactive Scheduling Method for Maintenance
15.3.1 Problem Definition
15.3.2 Solving Method
15.3.3 PSM Computational Model
15.3.3.1 Transfer to Process s Without Wait Time
15.3.3.2 Transfer to Process s After Some Wait Time
15.3.4 PSM Solution by Multi-Start/Greedy Method
15.3.4.1 Algorithm Flow in Proposed Method
15.3.4.2 Optimization by Multi-Start/Greedy Method
15.3.5 Experimental Results and Application Trial
15.3.5.1 Effectiveness Verification by Numerical Experiment
15.3.5.2 Comparative Experiment Results with Lagrangian Decomposition Coordination
15.3.5.3 Application Trial Result to Actual Production System
15.3.6 PSM Summary
15.4 Summary
Acknowledgments
References
16 Managing Design Change with Functional Blueprints
Abstract
16.1 Introduction
16.1.1 Comparison with Alternative Approaches
16.2 Functional Blueprints
16.2.1 Application to Electromechanical Design
16.2.2 Diagnosis and Assistive Design
16.3 Adapting Electromechanical Designs
16.3.1 Convergence of Functional Blueprint Networks
16.3.2 Parametric Versus Qualitative Design Changes
16.3.3 Reusability of Functional Blueprints
16.4 Expanding the Plasticity of Design
16.5 Applications and Open Problems
References
Part V Cost, Uncertainty, Risk,and Standards
17 Obsolescence Management
Abstract
17.1 Introduction
17.2 Cost of Obsolescence
17.3 How to Manage Obsolescence
17.3.1 Obsolescence Mitigation Strategies
17.3.2 Obsolescence Resolution Approaches
17.4 Obsolescence Cost Estimating Framework
17.5 Discussion and Conclusions
References
18 Planning to Extend the Life of Major Assets: Metro Rail Example
Abstract
18.1 Introduction
18.2 Objectives
18.3 Lifecycle Reliability Engineering
18.4 Asset Management Planning
18.5 Preparation
18.6 Data Gathering
18.7 Data Analysis
18.8 Root Cause Analysis
18.9 A3 Problem Solving Process
18.10 Reliability Growth Plan (RGP)
18.11 Asset Management Planning
18.12 Reliability Centred Maintenance (RCM)
18.12.1 Asset Management Planning, a Reprise
18.12.2 Whole Life Cost Model (WLCM) Methodology
18.12.3 WLCM Inputs
18.12.4 Asset Definition
18.12.5 WLCM Asset Definition Example
18.12.6 Maintenance Costs
18.12.7 Whole Life Cost Model---Input Data
18.12.8 Whole Life Cost Model---Output Data
18.13 Conclusions
Reference
19 Identification of Risks Related to Integrated Product Service Offerings of Rail Infrastructure: A Swedish Case
Abstract
19.1 Introduction
19.2 Integrated Product Service Offerings
19.3 Methodology
19.3.1 Individual Interviews
19.3.2 Group Interview
19.4 Rail Infrastructure Procurement in Sweden
19.5 IPSOs for Rail Infrastructure
19.6 Identified Risk Aspects
19.6.1 Size, Duration and Quality of the IPSO Contracts
19.6.2 Risk Allocation in Contracts
19.6.3 Supply Chain Management in IPSO Contracts
19.7 Discussion of Contractual Aspects of IPSO Contracts
19.7.1 Allocation of Risk in IPSO Contracts
19.7.2 The Need for Renegotiations
19.7.3 Lack of Information
19.7.4 Evaluation During and After the Contract
19.8 Discussion of Organizational Aspects of IPSO Contracts
19.8.1 Supply Chain Considerations
19.8.2 Change of Mindset
19.8.3 Lack of Trust
19.9 Concluding Discussion
19.9.1 This Work in a Larger Context
19.9.2 Further Research Is Needed
Acknowledgments
References
20 Managing Obsolescence Risk
Abstract
20.1 Introduction
20.2 Forecasting Obsolescence
20.2.1 Data Mining Based Obsolescence Forecasting
20.2.1.1 Sales Curve Forecasting for Parts with Evolutionary Parametric Drivers
20.2.1.2 Procurement Life Modeling
20.3 Obsolescence Management
20.3.1 Reactive Obsolescence Mitigation
20.3.2 Strategic Obsolescence Management
20.4 Software Obsolescence
20.5 Human Skills Obsolescence
20.6 Discussion
References
21 TES Service Innovation and the Role of Standards
Abstract
21.1 Introduction
21.2 Scope of TES, and Importance of the Service Context
21.3 The Role of Standards in Business Model Innovation
21.4 Standards Applicable to TES and Tailoring Guidelines
21.5 Value-Driving Activities and Processes---A Framework Standard for TES
21.5.1 Value and Risk
21.5.2 Forecast Demand
21.5.3 Set Maintenance Strategy
21.5.4 Manage Resources
21.5.5 Manage the Eco-system
21.5.6 Continuous Improvement and Enabling Activities
21.5.7 Guidelines on Tailoring the Value Map
References
Part VI Autonomous Maintenance
22 Building Dependable Electronic Systems for Autonomous Maintenance
Abstract
22.1 Introduction
22.2 Basic Concepts and Motivation
22.2.1 Sources of Errors
22.2.2 Deployment
22.2.3 Key Performance Metrics
22.3 Deployment of Redundant Resources
22.3.1 Spatial Redundancy
22.3.2 Temporal Redundancy
22.3.3 Information Redundancy
22.4 Platforms for Self-repair
22.4.1 Key Strategies
22.5 Potential Impact and Uptake of Autonomous-Maintenance
22.5.1 Test and Verification
22.5.2 Potential Impact and Uptake
23 Autonomous Maintenance for Through-Life Engineering
Abstract
23.1 Introduction
23.2 Maintenance, Repair and Overhaul
23.3 Automation Within Industrial Maintenance
23.4 Maintenance Task Classification
23.4.1 Class 222 Diesel Engine Train Undercarriage Maintenance
23.4.2 Task Classification for Maintenance: Outcomes and Discussion
23.5 Integrating Automation and Robotics into Maintenance
23.6 Design Strategies for Autonomous Maintenance, Self-healing and No Fault Found
23.6.1 Autonomous Maintenance
23.6.2 Self-healing
23.6.3 No Fault Found
References
Part VII Future Challenges and Opportunitiesin TES
24 New Approaches to Through-Life Asset Management in the Maritime Industry
Abstract
24.1 Full Service Business Model in the Maritime Industry
24.1.1 Introduction
24.2 Adaption to the Maritime Industry
24.3 Business Model Assessment
24.4 Condition Monitoring
24.4.1 The Concept of Condition Monitoring
24.4.2 From Condition Monitoring to Condition-Based Maintenance
24.4.3 Technical Implementation
24.4.4 Results of the Case Study
24.5 Synergies of a Combined Approach
24.6 Conclusions
Acknowledgement
References
25 Future Challenges and Opportunities in Through-Life Engineering Services and Concluding Remarks
Abstract
25.1 Introduction
25.2 Sources Consulted for the Identification of Future Challenges and Opportunities Relating to TES
25.3 Findings from the Review of Data Sources
25.3.1 Findings from the Literature
25.3.2 Findings from the Initial `Think Tank' (Chap. 1)
25.3.3 Survey of UK Based Manufacturers
25.3.4 Findings from Network Event and Forum Held at the I.Mech.E (London---July 2014)
25.4 Concluding Remarks
References
Appendix A Cyber Security and the Internetof Things (IoT)

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