tes conf2012 presentation

The EPSRC Centre for Innovative Manufacturing in

Through-lifeEngineering Services

A Multi-sector National Centrewww.through-life-engineering-services.org

EPSRC Centre in Through-life Engineering Services

Study of the cross sector challenges in Through-life Engineering Services feedback to design and

manufacture

©Cranfield University/L. E. Redding


Research aim

The aim of this research project is to investigate cross sector challenges in maintenance, repair and overhaul (through-life engineering services) to improve availability, predictability and reliability of high value products while reducing the service cost. This project will also establish the current state of feedback between engineering services and design, and engineering services and manufacturing.



Project 1 – Research Team

Professor Ashutosh Tiwari

Dr Louis ReddingPicture pending


Project 1 – Research Questions

1. What are the major challenges and opportunities within the areas of maintenance, repair, and overhaul (MRO) across industrial sectors?

2. What are the major challenges and opportunities in service feedback to design and manufacturing functions across sectors?

3. How can case studies be captured where design and manufacturing impact service performance and as a result cost?

4. How can the identified challenges and opportunities be mapped against current tools to identify the knowledge gaps?

5. How can the EPSRC Centre support a wide range of requirements (Lower and higher TRL level research and product development, education, standards etc) from industry within through-life engineering services?



Overview of Project 1

Literature search

Industrial survey

2 Case Studies

Inputs

Outputs

Key words and search

strings

Structured interviews,

direct observation, and review of company

data

Population data and

questionnaire informed by

the literature

Knowledge of the state of the art in

Through-life Engineering

Services

Practitioner awareness of the concept

and the perceived

benefits/issues

Knowledge of how Through-

life Engineering Services are

developed and operate

• Publications• Reports• Awareness• Mapping



Survey

• Two approaches

Survey(2 Approaches)

Postal surveyTargeting UK based manufacturing organisations

On line open survey


Identification of the postal survey population

The search parameters The population

304 companies after review of organisational websites

1837 Companies who have a

turnover ≥ £10 million

77710 companies who have

manufacturing operations in the

UK

2,752,710 Companies based

within the UK

Geographic location

Turnover

United Kingdom

≥ 10 millionGBP

Every SIC code included if referring to

manufacturing

Population of manufacturing organisations who may possess the potential to offer through life

engineering services

Industrial sector by SIC

code



Survey Response rate

• Two approaches

Survey(2 Approaches)

Postal surveyTargeting UK based manufacturing organisations

On line open survey


Poor ≥0.5%

51 Companies


Reasons cited for non-response

• Administrations and liquidations• “Cannot identify key personnel within organisation to

whom this applies”• “We have no interest in through-life service

provision” – [Major European Car Manufacturer]• “We do not respond to surveys”



Survey Results(On line - Questionnaire)


Company presence by sector

Aerospace; 44

Agriculture; 1Automotive; 3

Civil/Construction; 1

Defence; 11

Electronics; 3

Energy; 3

Marine; 3

Nuclear; 5

Oil & Gas; 3Power; 1 Security; 1 Telecoms; 2


Some companies have a presence in several sectors

Ref: Redding et al (2012)


Description of organisations responding to ‘On line’ survey



Aerospac

e

Agricultur

e

Automoti

ve

Civil/Construction

Defense

Electronic

sEner

gyHeal

thMarine

Minerals

Extraction

Nuclear

Oil/Gas

Power

Security

Telecoms

Original Equipment Manufacturer 9 0 1 1 5 1 1 0 1 0 3 1 0 1 1

Tier 1 Supplier (Supplies directly to OEM) 8 0 1 1 3 2 1 0 1 0 3 1 0 1 1

Tier 2 Supplier (Supplies to Tier 1) 7 0 2 1 3 2 2 0 1 0 3 2 1 1 2

Others 28 1 2 0 5 1 2 0 3 0 1 1 1 1 1

Organisational Structure & major customers

Division of a multi-national company; 25

A publically listed company; 5

A diivision of a publi-cally listed company;

4

A Private company; 22


Government agencies ; 29

Public/Private Companies, 36

Consumers (B2C);

10

CustomersSome companies have a

presence in several sectorsRef: Redding et al (2012)

Organisation Structure


Interest in maintenance appears to be growing

• 64% Are manufacturers who conduct in house maintenance activities

• 36% Are manufacturers who stated that they did not conduct maintenance activities




Method of initiating MRO activities by sector



Aerospac

e

Agricultur

e

Automoti

ve

Civil/Constructi

onDefense

Electronic

sEner

gyHealt

hMarine

Minerals

Extraction

Nuclear

Oil/Gas

Power

Security

Telecoms

Time based maintenance systems 14 0 0 0 4 3 0 0 1 0 1 1 0 1 0Reliability based maintenance systems 9 0 0 0 3 2 0 0 1 0 1 0 0 1 0Usage based maintenance systems 9 0 0 0 2 2 0 0 1 0 1 0 0 1 0Condition monitoring systems 9 0 0 0 3 2 0 0 1 0 2 0 0 1 0We do not trigger MRO activities 6 0 1 1 3 0 1 0 1 0 1 1 0 0 1No Answer 21 1 2 0 3 0 2 0 1 0 2 1 1 0 1

Notes!1. CT and MRI Scanners etc!!2. Mining Condition Monitoring Tools!!!

2. Not even in their asset

management!!!

1. Not even in their asset

management!!!


Method of recording MRO data within respondent organisations

Paper files

Elecronic files

Electronic databases

RFID related technology

Remote data collection via telecoms

Remote data collection via satellite

Hand held portable devices

None

Others

0 2 4 6 8 10 12 14 16 18 20


Number of companies



Nature of data content as advised by practitioners

• “Failure categorization”• “Failure modes and wear patterns….[which]…are fed back to

improve future designs and upgrades”,• “…faults that get tracked back to design docs and previous repairs”,• “Helicopter support is generally quite open loop with little obvious

integration with MRO chain and little obvious constructive feedback of any kind aimed at reducing life cycle cost”,

• “…outcome of special inspections MTBR”,• “Performance data MTBF”,• “..performance data, failure categorization, physical attributes,

photos, initial root cause analysis…..”,


Cross tabulation of data usage and mode of collection

Paper

files

Electr

onic files

Electr

onic data

base

RFID te

chnology

Remote

data co

llecti

on via t

eleco

mmunications

Remote

data co

llecti

on via s

atellit

e communica

tions

Hand held

portable

device

s (lap

tops, scan

ners et

c)None

Other0

5

10

15

20

25

30

35

OtherNot usedUsage MonitoringTime based MRO systemsSpares and inventory acquisitionBilling

Prognostics


Challenges relating to the capture of MRO data




The use of MRO data by sector

©Cranfield University/L. E. Redding Ref: Redding et al (2012)

Aerospac

e

Agricultur

e

Automoti

ve

Civil/Construction

Defense

Electronic

sEner

gyHeal

thMarine

Minerals

Extraction

Nuclear

Oil/Gas

Power

Security

Telecoms

Billing 14 0 0 0 4 3 0 0 1 0 1 1 0 1 0

Spares and inventory acquistion 12 0 0 0 4 2 0 0 1 0 2 0 0 1 0

Time based MRO systems 10 0 0 0 2 2 0 0 1 0 1 0 0 1 0

Usage monitoring 11 0 0 0 4 3 0 0 1 0 1 1 0 1 0

Not used 1 0 0 0 1 0 0 0 1 0 0 0 0 0 0

Other 7 0 1 1 1 0 1 0 0 0 1 1 0 0 1

No answer 21 1 2 0 3 0 2 0 1 0 2 1 1 0 1


Status of data feedback


Design function

Manufacturing function

Service & Use Functions

64% Yes36% No

68% Yes32% No

3rd Party Maintenance Facility

68% Yes32% No

Un-Known at this point


Perceived opportunities by sector



Conclusions


Findings from the survey dataFinding No. Finding Description

1. Although there is continuing growth cited within the literature relating to pro-active MRO initiatives, the data suggests that such activities for the majority of manufacturing organisations responding to the survey appear to remain reactionary only being triggered by customer request.

2. The data suggests that there is no clearly defined universal method adopted by MRO activities for the collection of data with such functions using a variety of data collection protocols and methods.

3. Within the organisations surveyed the majority of organisations state that they do feedback MRO data to their design and manufacturing functions (either ‘in house’ or external). This implies that such data is technology/usage based rather than being purely commercial or administrative.

4. There appears to be a misalignment relating to the needs of the end user of MRO data (manufacturing and design functions) and the systems abilities to provide accurate and timely responses (technical and usage data) and related information.

5. Challenges exist relating to the quantity, quality and completeness of data. Respondents to the survey suggest that there is too much data, it is fragmented and of poor quality in many cases and not complete.




Findings from the data

Finding No. Finding Description

6. Within the MRO field relating to through-life engineering services, there are no clear definitions, ontology or taxonomy which can assist in the categorisation of data, information and ultimately knowledge.

7. There are issues relating to incomplete understanding of product and component performance due to intermittent failures and error signals in MRO systems. This skews the data and can affect decisions relating to MRO strategies.

8. Although organisations stated that they collected MRO data its content, structure, storage and retrieval appears to be ad’hoc in all but a few leading world class OEM’s. The data is unduly skewed by the existence of NNF recording within the data, the effect of which is not clear or widely known.

9. Condition based monitoring/management and RFID technology are identified as being the key opportunities within the field of through-life engineering services.




12 Findings from the dataFinding No. Finding Description

10. Interest in through-life engineering services continues to grow. The majority of organisations responding to the survey state that they have plans to move into through-life engineering services with a greater majority stating that they have plans to extend the use of acquired MRO data and use this to inform the manufacturing and design functions within their organisation.

11. Whilst there are undoubtedly significant challenges and opportunities relating to the successful adoption of through-life engineering services the perceived threats to this successful adoption within the practitioner base responding to the survey relate to data management issues arising from the lack of standards, procedures, and supporting structures.

12. The greatest perceived opportunity that through-life engineering services offers is seen to be in the field of prognostics leading to faster mitigation relative to degrading products.




Our Partners

Questions: Louis Redding, Project Manager/Research Fellow on 01234 750111 ex 2283 or at [email protected]

tes conf2012 presentation

Documents

epsrc centre

engineering servicesand

research project

sector national centre

major challenges

research questions1

crosssector challenges

identified challenges