Integrated framework for a cost-effective and ease of Repair, Renovation and Re-use of machine tools within modern factory

Integrated framework for a cost-effective and ease of Repair, Renovation and  Re-use  of machine tools within modern factory
Summary

EASE-R3 focuses on the selection of the best maintenance strategy, including decommissioning, such as renovation, repair, re-use, according to the minimization of Life Cycle Cost (LCC) and Life Cycle Assessment (LCA) related parameters.

Once the selection is performed, EASE-R3 then investigates different technologies supporting maintenance tasks such as Augmented Reality (AR)-based, Virtual Reality (VR), Condition monitoring, etc.

Current maintenance policies can be useful in answering effectiveness questions such as “How can this particular machine be operated more efficiently?”,

 

EASE-R3 answers to the 5 top questions of effectiveness:. How can reliability, repair and EOL be included in a robust and integrated Life Cycle Cost and Life Cycle Assessment model of the factory?

PLATFORM A: Integrated Life Cycle Cost and Life Cycle Assessment platform based on Reliability & Maintainability simulations model and techniques Which are the most cost-effective and optimal Repair strategies we should tailor for sets of components/machines of the factory?

PLATFORM B: Repair Decision Support System platform for optimal cost-effective maintenance strategy selection Which machine and/or components should we improve and how can we reduce repair time and cost?

PLATFORM C: Seamless approach to reduce Repair time and cost of machines and components Which are the most environmental-effective EOL strategies we should tailor for sets of components/machines of the factory?

PLATFORM D: Decommissioning Decision Support System (DDSS) platform to select optimal and environmental effective EOL strategies How can we assess the remaining life of Re-usable components and which are most valuable Renovation technologies for the machine tools?

PLATFORM E: Enabling technologies for energy & cost effective Re-use and Renovation of machine tools

More information
Web resources: http://www.easer3.eu/
https://cordis.europa.eu/project/rcn/108952/factsheet/en
Start date: 01-07-2013
End date: 30-06-2016
Total budget - Public funding: 6 212 662,00 Euro - 4 429 989,00 Euro
Call topic: Innovative strategies for renovation and repair in manufacturing systems (FoF.NMP.2013-8)
Location
    Comment: Demonstrator 3 – Predict remaining useful life The level of confidence of prediction has been evaluated by inducing real machine failure, in order to compare prediction and actual failure. Avoid or better anticipating failures it will cost less then if the same failure occurs during normal operation also collateral damage like scrap parts will be reduced
      Comment: Interactive immersive technologies for process planning (i.e. fixturing sequencing), has been developed; it is envisaged to use commercial of the shelf software (COTS) and to enhance its functionality by developing add on modules. Especially discrete event, using plant simulation software such as Lanner’s Witness, will be used to asses and optimize the sequencing of processes.
      Comment: The developed framework aims at: 1) increases the Overall Equipment Effectiveness (OEE) due to better coordination of repair cycles and improved component useful life-time utilisation 2) Reducing of Total Cost Of Ownership (TCO) through reduced amount of stored spare parts
      Comment: The EU-funded project is focused on the selection of the best maintenance strategy, including decommissioning, according to the minimization of Life Cycle Cost (LCC) and Life Cycle Assessment (LCA).
        Comment: Demonstrator 5 – Re-usability and renovation Validation of re-usability of components and Renovation approach based on multifunctional add-on modules
      Comment: Demonstrator 3 – Predict remaining useful life Validation of residual life prediction of components/machines based on CNC control internal signal processing The developed of prediction algorithms and condition monitoring strategies applied to the available machines tools. Different strategies and algorithms have been compared regarding their performance to detect the failure mode and time, together with the associated confidence of prediction.
      Comment: Demonstrator 5 – Reusability and renovation Validation of re-usability of components and Renovation approach based on multifunctional add-on modules. The new multifunctional add-on modules has been integrated into a selected machine tool, thanks to these new intelligent modules the destination of use of a machine can be changed giving the possibilities have further options for decommission.
      Comment:

      Demonstrator 2 – DDSS Validation of Life Cycle Cost (LCC) analysis integrated with Life Cycle Assessment (LCA) and Decommissioning Decision Support System. The End OF Life (EOL) decision support requires the maintenance history of a machine tool . A special and dedicated SW module is in charge of collecting the necessary informations related to components directly from the machines control system.

      Comment:

      Demonstrator 1 - RDSS Validation of Life Cycle Cost (LCC) analysis integrated with Reliability and Maintainability (R&M) simulation and Repair Decision Support System Tools/methods applies to evaluate the MTBF, MTTR and LCC of machines identified among end-users

      Comment: Augmented Reality-based tools and the remote assistance platform have been used to support operators in maintenance and repair procedures. Virtual Realty based Re-Manufacturing Interactive immersive technologies for process planning (i.e. fixturing sequencing), has been developed using commercial off the shelf software. Operational simulation (i.e. cnc machine program simulation), layout optimization of factories and or workcells can be carried out and helping to achieve a more productive and safer working environment.