UNIFIED PREDICTIVE MAINTENANCE SYSTEM

UNIFIED PREDICTIVE MAINTENANCE SYSTEM
Summary

UPTIME will seek to reframe predictive maintenance strategy by proposing a unified framework and to create an associated unified information system in alignment to the aforementioned framework. Therefore, UPTIME will extend and unify new digital, e-maintenance services and tools in order to exploit the full potential of a predictive maintenance strategy with the UPTIME solution, will deploy and validate the UPTIME solution in the manufacturing companies participating in the UPTIME consortium and will diffuse the UPTIME solution in the manufacturing community. UPTIME will enable manufacturing companies having installed sensors to fully exploit the availability of huge amounts of data with respect to the implementation of a predictive maintenance strategy. Moreover, production, quality and logistics operations driven by predictive maintenance will benefit from UPTIME. UPTIME will enable manufacturing companies to reach Gartner's level 4 of data analytics maturity (optimized decision-making) in order to improve physically-based models and to synchronise maintenance with quality management, production planning and logistics options. In this way, it will optimize in-service efficiency through reduced failure rates and downtime due to repair, unplanned plant/production system outages and extension of component life. Moreover, it will contribute to increased accident mitigation capability since it will be able to avoid crucial breakdown with significant consequences. Consequently, UPTIME will exploit the full potential of predictive maintenance management and its interactions with other industrial operations by investigating a unified methodology and by implementing a unified information system addressing the predictive maintenance strategy.

More information
Website: https://www.uptime-h2020.eu/
Duration: 36 months
Start date: 01-09-2017
End date: 31-08-2020
Number of participants: 11
Total budget - EC contribution: 6248367 Euro - 4847836 Euro
Call topic: Novel design and predictive maintenance technologies for increased operating life of production systems (FoF.2017.09)
Instrument: Innovation Action (IA)
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Characteristics

Significant innovations, use case requirements and lessons learned - (2) view

    Comment:

    UPTIME will develop a versatile and interoperable unified predictive maintenance platform for industrial & manufacturing assets from sensor data collection to optimal maintenance action implementation. Through advanced prognostic algorithms, it predicts upcoming failures or losses in productivity. Then, decision algorithms recommend the best action to be performed at the best time to optimize total maintenance and production costs and improve OEE.

    UPTIME innovation is built upon the predictive maintenance concept and the technological pillars (i.e. Industry 4.0, IoT and Big Data, Proactive Computing) in order to result in a unified information system for predictive maintenance. UPTIME open, modular and end-to-end architecture aims to enable the predictive maintenance implementation in manufacturing firms with the aim to maximize the expected utility and to exploit the full potential of predictive maintenance management, sensor-generated big data processing, e-maintenance, proactive computing and industrial data analytics. UPTIME solution can be applied in the context of the production process of any manufacturing company regardless of their processes, products and physical models used.

    Key components of UPTIME Platform include:

    1. SENSE deals with data agreegation from heterogeneous sources and provides configurable diagnosis capabilities on the edge.
    2. DETECT deals with intelligent diagnosis to provide a reliable interpretation of the asset's health.
    3. PREDICT deals with advanced prognostic capabilities using genering or tailored algorithms.
    4. ANALYZE deals with analysis of maintenance-related data from legacy and operational system.
    5. FMECA (Failure Mode, Effects and Criticality Analysis) deals with estimation of possible failure modes and risk criticalities evolution.
    6. DECIDE deals with continuously improved recommendations based on historical data and real-time prognostic results.
    7. VISUALIZE deals with configurable visualization to facilitate data analysis and decision making.
    Comment: The UPTIME Platform is deployed and validated against three industrial use cases:  (1) production and logistics systems in the aviation sector - FFT, (2) white goods production line - WHIRLPOOL  and (3) cold rolling for steel straps - MAILLIS.     The FFT use case deals with maintenance in highly complex transportation asset operations, some of which are mobile and subjected to diverse environments and a wide range of unpredictable environmental stress factors. Due to the critical nature of the deployment of these assets, the requirements are both technically and organisationally very high. The need has arisen to increase efficiency in maintenance execution as well as in reporting to the client, who in most of FFT projects is responsible for the logistics coordination of their assets.      The Whirlpool use case deals with the newly installed production line for clothes dryers, a complex automatic production line, which puts steel coils through a sequence of several steps of straightening, punching, seaming, flanging and screwing to eventually form the drum that holds and rotates the clothes in the dryer. The drum production equipment is very complex, highly automated and critical from many perspectives. It is critical to ensure the highest possible quality of the drum, which is the core component of the clothes dryer. At the same time, it is vital to keep the production equipment running efficiently and keep costs under control.     The Maillis use case deals with cold rolling mill for the production of steel strapping. MAILLIS‘s offer combines high-quality packaging materials and state‐of‐the‐art technology, ensuring that metal producers enjoy reliable, durable, proven and high‐speed strapping and wrapping technology at the optimal cost. MAILLIS uses cold rolling mills to produce rolling products with the smallest possible thickness tolerances and an excellent surface finish. The demand for changing over the milling rollers comes from either their regular wear or from an unexpected damage, which can occur due to either a defective raw material or an equipment malfunction. This usually happens every eight hours for the work rolls and every week for the backup rolls. After several regrinding, the diameter of the roll becomes so small that the rolls are no longer useful. It is expected to have a machine that reports its current health status along with the appropriate data analytics and metrics. UPTIME should also allow predictions about equipment‘s future health as well as recommendations for future actions and enable machines performing self-assessment, on which decision-making can be followed to advance equipment maintenance and facilitate the machine components and products life cycle.    

Added value and impact - (7) view

    Comment:

    UPTIME will provide a unified predictive maintenance management framework and a smart predictive maintenance information system covering the whole prognostic lifecycle. The UPTIME solution will be applicable to any production system incorporating sensors and will be based on real-time reliability-related (prognostic) information in order to reduce the equipment downtime and malfunctions with the aim to produce high-quality products with optimized losses. It will utilize sensors for measuring various parameters of the production process, provide diagnostic outcomes, i.e. the current equipment health state, generate predictions about future equipment behaviour, and recommend optimal actions at optimal times. It will also incorporate a continuous improvement mechanism for continuous learning of Diagnosis, Prognosis and Maintenance Decision Making phases triggered by sensor data during maintenance and other operational actions implementation. The elimination of unexpected failures will lead to an increased level of safety in the workplace and to improved overall operations efficiency.

      Comment:

      The UPTIME solution will combine and extend existing predictive maintenance tools and services (USG/BIBA, preIno/BIBA, PANDDA /ICCS, SeaBAR/Pumacy, and DRIFT/RINA-C) and will define the way for its implementation in a systematic and unified way with the aim to fully exploit the advancements in ICT and maintenance management by examining the potential of big data in an e-maintenance infrastructure.

      Extended version of USG will implement the Signal Processing phase; extended version of preInO will address the Diagnosis and the Prognosis phases; extended version of PANDDA will deal with Maintenance Decision Making; extended version of SeaBAR will address the Maintenance and Operational Actions Implementation; and extended version of DRIFT will deal with data-driven FMECA.

      Each extended UPTIME service will incorporate real-time data-driven information processing technologies and algorithms so that the integrated system is able to cover complete scenarios and fulfil the needs of the manufacturing companies participating in the consortium. The aforementioned tools will interact when necessary to the manufacturing company’s system (e.g. ERP, MES) in order to exchange data and information for scheduling production, quality and logistics activities together with maintenance activities (e.g. by using the production plan of the ERP system). Through the Continuous Improvement mechanism, UPTIME will be able to continuous learn with the aim to update and improve Diagnosis (Detect), Prognosis (Predict) and Maintenance Decision Making (Decide) phases by gathering actions-related and/ or failure-related sensor data (Act).  

      Comment:

      UPTIME aims to deliver novel e-maintenance services and tools to support the daily work of maintenance engineers as well as the overall maintenance management with the aim to optimize in-service efficiency. UPTIME solution consists of extended e-maintenance services and tool, which will incorporate novel methods and algorithms for addressing the phases of the UPTIME framework and conclude in a novel predictive maintenance solution covering the whole prognostic lifecycle.

      Comment:

      UPTIME will be able to be applied in the context of the production process of any manufacturing company regardless their processes, products and physical model used. It will take advantage of predictive maintenance management, industrial IoT and big data, as well as proactive computing and the e-maintenance concept in order to reframe predictive maintenance strategy and to create a unified information system in alignment to the new predictive maintenance strategy framework and to Gartner’s 4 levels of data analytics maturity.

      UPTIME will be applicable at the level of component, machine and production system, depending on the placement of sensors throughout the production lifecycle and the data availability in the manufacturing company’s systems (e.g. Enterprise Resources Planning- ERP, Manufacturing Execution System- MES). Within UPTIME, there will be interactions between the various e-maintenance services and the e-operations data and information from the manufacturing companies’ systems in order to synchronise maintenance with production, quality and logistics management. The results of the UPTIME solution will be evaluated by the manufacturing companies participating in the consortium and will be demonstrated in manufacturing companies beyond the consortium.

      Comment:

      Through its unique bundle of a predictive maintenance management framework and an integrated platform, UPTIME will prevent critical asset failure, deploy resources more cost-effectively, maximize equipment uptime and enhance operations, while accelerating the quality and supply chain processes. By better diagnosing, anticipating and acting upon the asset performance and product quality, the UPTIME novel predictive maintenance framework is expected to increase in-service efficiency by at least 10% in the 3 pilot cases through combined KPIs measurements.

      By investigating and demonstrating the applicability of the UPTIME predictive maintenance system in three pilot cases in different manufacturing sectors, UPTIME will contribute to a more widespread adoption of predictive maintenance and demonstrate more accurate, secure and trustworthy techniques at component, machine and system level.

    Comment:

    The economic impact of UPTIME is the most important one and can be seen at 2 levels :

    • Short/mid-term impact: improvement of financial results of industrial companies and their competitiveness thanks to better operational performance (optimized maintenance and production)
    • Mid/long term impact: the improved competitiveness will help to reconquer some market shares and then reinforce an offensive marketing strategy (low margin segments could be reprioritized)

Technologies and enablers - (24) view

    Comment:

    The UPTIME platform will leverage crucial, and often hidden, data from machines and systems in real time and substantiate the benefits of advanced predictive maintenance analytics in boosting asset availability and service levels in manufacturing operations. Moreover, UPTIME delivers new ways for effective operational risk management in terms of preventing unexpected failures of a manufacturer’s assets, and effectively planning maintenance actions, thereby transforming the mentality of manufacturing industries in respect to maintenance services. With the help of the end-to-end UPTIME smart diagnosis-prognosis-decision making methods, manufacturers become leaner, more versatile and better prepared to act upon accidents and unexpected incidents in their everyday operations. The increased accident mitigation capabilities they acquire, allow them not only to accelerate the workplace safety and improve the workers’ health,
    but also to reduce the incurring costs and become more competitive.

      Comment:

      UPTIME platform focusses on the use of condition monitoring techniques, e.g. event monitoring and data processing systems, that will enable manufacturing companies having installed sensors to fully exploit the availability of huge amounts of data and to handle the real-time data in complex, dynamics environement in order to get meaningful insights and to decide and act ahead of time to resolve problems before they appear, e.g. to avoid or mitigate the impact of a future failure, in a proactive manner. Moreover, UPTIME proposed unified framework will not be limited to monitoring and diagnosis but it aims to cover the whole prognostic lifecycle from signal processing and diagnostics till prognostics and maintenance decision making along with their interactions with quality management, production planning and logistics decisions.

    Comment:

    UPTIME will reframe predictive maintenance strategy in a systematic and unified way with the aim to fully exploit the advancements in ICT and maintenance management by examining the potential of big data in an e-maintenance infrastructure taking into account the Gartner’s four levels of data analytics maturity and the
    proactive computing principles.

      Comment:

      UPTIME Platform is developed accroding to unified predictive maintenance framework and an associated unified information system to enable the predictive maintenance strategy implementation in manufacturing industries. The UPTIME predictive maintenance system will extend and unify the new digital, e-maintenance services and tools and will incorporate information from heterogeneous data sources, e.g. sensors, to more accurately estimate the process performances. The UPTIME predictive maintenance platform is developed mainly based on five baseline e-maintenance services and tools:

      • USG (Universal Sensor Gateway): USG serves as a modular data acquisition and integration device to the Product Lifecycle Management (PLM) ecosystem of a product
      • preInO: The preInO Processing Engine is able to detect and predict the state of a whole system or components with respect to mechanical systems such as windturbines, special-purpose vehicles, production machinery, etc.
      • PANDDA (ProActive seNsing enterprise Decision configurator DAshboard): PANDDA is a software service that implements (i) proactive decision methods to provide recommendations about mitigating (perfect or imperfect) maintenance actions and the time for their implementation on the basis of real-time prognostic information; and (ii) a Sensor-Enabled Feedback (SEF) mechanism for continuous improvement of the generated recommendations.
      • SeaBAR (Search Based Application Repository): SeaBAR is a modular software platform built on Big Data and Enterprise Search technology. The SeaBAR platform supports end users by means of data aggregation, data analysis and visualization.
      • DRIFT (Data-Driven Failure Mode, Effects, and Criticality Analysis (FMECA) Tool): DRIFT is a tool that, on the basis of the information gathered in other modules (maintenance data, production, logistics, quality data) use them to identify what are the Failure Modes, Effects and Criticalities of the components and system according to literature available and novel correlation algorithms among modes failures, effects and critical impacts.
        Comment:

        UPTIME_VISUALIZE (extended version of SeaBAR prototype) component is responsible for the intuitive and uninterrupted human-machine interaction. The user interfaces, including the analytics dashboards and the notificaiton engine, will be customised or further developed in full accordance with the end-user business case. Taking an example ofthe  UPTIME White Good business case for complex automatic production line to produce drums for dryer, the generation of early warnings to suggest autonomous activities to factory workers should be communicated through mobile devices or on-board devices.

        Comment:

        The data visualisation in UPTIME is performed by the UPTIME_VISUALIZE (SeaBAR prototype) component:

        • By establishing standardised connectors to the key data/information/knowledge sources for maintenance, production planning, logistics and quality management.
        • By faceting, filtering and semantic structuring of the collected data according to maintenance viewpoints.
        • Context-sensitive, interactive visualizations in order to allow the end user to easily search and navigate through huge amounts of heterogeneous information with the aim to enable a maximum flexible analysis of all relevant information, e.g. to drill-down into the data according to a region, timeframe and machine or to generalise a specific critical situation and find similar (past) situations with appropriate measures and individual user experience (e.g. best practices).
        • A customizable dashboard focusing on the specific information needs of e.g. maintenance engineers, quality managers and upper management by different context specific visualization and analytics tools.
        • Continuous visualization of critical data and utilization of captured experience from past situations for providing useful insights in interaction with manufacturing companies’ systems.
        • By turning from generic statistical data towards instance-specific data and enabling instance specific diagnosis and prognosis.
      Comment:

      UPTIME will enable manufacturing companies to reach Gartner's four levels of data analytics maturity for optimised decision making - each one building on the previous one: Monitor, Diagnose and Control, Manage, Optimize - aims to optimise in-service efficiency and contribute to increased accident mitigation capability by avoiding crucial breakdowns with significant consequences. UPTIME Components UPTIME_DETECT & UPTIME_PREDICT and UPTIME_ANALYZE aim to enhance the methodology framework for data processing and analytics. The key role for the UPTIME_DETECT and UPTIME_PREDICT components are data scientists who are in charge of developing, testing and deploying algorithmic calculations on data streams. In this way, the component is able to to identify the current condition of technical equipment and to give predictions. On the other hand, the UPTIME_ANALYZE is a data analytics engine driven by the need to leverage manufacturers’ legacy data and operational data related to maintenance, and to extract and correlate relevant knowledge.

        Comment:

        The "Persistence" layer in the UPTIME conceptual architecture includes a Database Abstraction Layer (DAL) and houses of relational database engine as well as a NoSQL database, where all information needed by the "User Interaction" and "Real-Time Procesing and Batch Processing" layers  (refer to UPTIME conceptual architecture) is stored and retrieved. For the raw sensor data itself, this data storage concept is enhanced by a database for time-series data to ensure efficient and reliable storage, while visualization functionalities will use an indexing database to facilitate the exposure of analytics. In these databases, all information needed by the other three layers is stored and retrieved. The UPTIME solution aims to provide data harmonization in terms of manipulating streaming data coming from the sensors. Based upon these needs a time series database is needed and in the context of UPTIME three instances of influxDB (one instance per business case) are installed. Along with the influxDB instances, a common MySQL database that will handle the operations of the UPTIME system is created.

          Comment:

          UPTIME has a common MySQL database that will handle the operations of the UPTIME system.

          Comment:

          UPTIME Data are stored in appropriate, shared databases (NoSQL, time-series-based, relational) according to a common UPTIME predictive maintenance model in order to facilitate homogeneous access.

        Comment:

        In UPTIME, two data processing solutions are considered. (1) Batch processing of data at rest, through massively paralle processing, (2) real-time processing of data in motion, real time data from heterogeneous sources are processsed as a continuous "stream" of events (produced by some outside system or systems), and that data processing occurs so fast that all decisions are made without stopping the data stream and storing the information first.

          Comment:

          UPTIME main functionalities are structured in three main modules, namely: edge, cloud and GUI modules.

          • The UPTIME edge module will ensure data collection from machines, sensors, etc. and sent it on for analysis. It may also include some additional functionalities which require real-time results.
          • The UPTIME Cloud module contains all the advanced functionalities of the solution, which do not require a real time result. There we will analyse the data collected on the edge, as well as data received from relevant information systems, and provide the expected predictions. “Cloud” can refer to remote servers or an internal cloud within the customer’s Plant or Enterprise, as is deemed necessary by the customer.
          • Lastly the GUI module, through which the user will interact with the previously mentioned functionalities, whether it is to view data or configure the solution.
            Comment:

            4 main components in the cloudbased infastructure of the UPTIME platform include:

            • UPTIME_DETECT and PREDICT component (extended version of PreIno prototype) processes mainly timeseries‐based data from the field, to give further context to the data, e.g. to detect topical conditions of technical equipment and to predict probable future conditions. 
            • UPTIME_ANALYZE (a new developed prototype) is a data analytics engine driven by the need to leverage manufacturers’ legacy data and operational data related to maintenance, and to extract and correlate relevant knowledge.
            • UPTIME_DECIDE component (extended version of PANDDA prototype) that implements a prescriptive analytics approach for proactive decision making in a streaming processing computational environment. It provides real-time prescriptions fo the optimal maintenance actions and the optimal time for their implementation on the basis of streams of predictions about future failures.
            • UPTIME_FMECA (extended version of DRIFT prototype) provides estimation of possible failure modes and risk criticalities evolution through its data-driven FMECA approach.
            Comment:

            UPTIME_SENSE component (USG prototype) is located in the edgebased infrastructure of the UPTIME platform. It aims to capture data from a high variety of sources and cloud environments. SENSE brings configurable diagnosis capabilities on the edge, e.g. for real-time or off-the-grid applications. SENSE addresses 3 high level functions:

            • Sensor signal processing, which collects the signals from equipment or other sensors, and pre-processes them before transmitting them on the cloud platform.
            • Edge diagnosis for optional state detection diagnosis for certain use cases.
            • Support functions for functions necessary for the correct operation of the edge module.
        Comment:

        The UPTIME_SENSE component is responsible for the acquisition of sensor data from the field. It is utilised to enable previously disconnected assets, to communication with the UPTIME Cloud.

        Comment:

        The current draft of the UPTIME data model is designed based on international standards like MIMOSA (OSA-CBM v3.3.1 and OSA-EAI v3.2.3a), the initial historical data provided by the business cases and the previous implementations of UPTIME_FMECA and UPTIME_DECIDE.

        Comment:

        UPTIME_ANALYZE is a data analytics engine driven by the need to leverage manufacturers’ legacy data and operational data related to maintenance, as well as to extract and correlate relevant knowledge. The data mining and analytics of ANALYZE component practically delivers the intelligence of the ANALYZE component by defining, training, executing and experimenting with different machine learning algorithms.

      Comment:

      To ease integration of all UPTIME components, the main programming language used by the components and the integrated platform is Java.

      Comment:

      The UPTIME conceptual architecture was designed according to the ISO/IEC/IEEE 42010 “System and software engineering – Architecture description” and mapped to RAMI 4.0 in order to ensure that it can be represent predictive maintenance in the frame of Industry 4.0.

      The UPTIME vision converges and synthesizes predictive maintenance, proactive computing, the Gartner’s levels of industrial analytics maturity and the ISO 13374 as implemented in MIMOSA OSA-CBM in order to create a consistent basis for a generic predictive maintenance architecture in an IoT-based industrial environment. In this way, the Operational Technology and the Information Technology can also be converged in the context of Industry 4.0.

        Comment:

        The UPTIME platform is built upon the predictive maintenance concept, the technological pillars (i.e. Industry 4.0, IoT and Big Data, Proactive Computing) and the existing baseline tools (i.e. USG, preInO, PANDDA, SeaBAR, DRIFT) resulting in a unified information system for predictive maintenance. The extended UPTIME baseline tools (SENSE, DETECT, PREDICT, DECIDE, ANALYZE, FMECA, VISUALIZE) will address the various steps of the unified predictive maintenance approach and will incorporate interconnections with other industrial operations related to production planning, quality management and logistics management.

      Comment:

      UPTIME will provide a unified predictive maintenance framework and an associated unified information system in order to enable the predictive meintenance strategy implementation in manufacturing firms with the aim to maximize the expected utility and to exploit  the full potential of predictive management, sensor generated big data processing, e-maintenance, proactive computing and the four levels of data analytics maturity. The unification of the novel e-maintenance services and tools in the context of the proposed framework will lead to overcoming of the existing commercial software and research prototypes limitations and will conclude in a novel predictive maintenance solution covering the whole prognostic lifecycle.

      Some limitiations of existing e-maintenance commercial software and research prototypes that will be addressed by UPTIME Platform, for example:

      • The majority of such prototypes and commercial systems focus on product maintenance, i.e. on the service stage of the PLM (e.g. warranty failures) and not on industrial maintenance, i.e. on the manufacturing stage of the PLM.
      • The developed systems are mainly based upon physical, domain-specific models that are not easily extensible for other equipment or for other industries.
      • They rarely exploit big data processing infrastructures for real-time, sensor data, since they usually use batches of data, while the level of data analytics maturity is usually low.
      • They do not allow the embodiment of domain knowledge in order to be used by appropriate methods and to be coupled with the real-time data.
      • Each one of them focuses on a specific aspect of predictive maintenance (e.g. condition monitoring, prognostics, maintenance spare parts) instead of having a unified approach for covering all the phases and related aspects in terms of industrial operations management.

       

Digitalisation pathways - (7) view

ICT performance characteristics - (13) view

Standards, standardisation and regulation - (5) view

    Comment:

    The standardisation goal in UPTIME is to simplify the integration of the components in the the UPTIME Platform and to make easier the integration of the UPTIME Platform in new industrial environments.

    Below list of some relevant standards to UPTIME:

    • IEC 62541 (OPC-UA) and ISO/IEC 20922 (MQTT) for  Modular Edge Data Collection & Diagnosis   - also JSON, XML, MSGPACK, I2C, SPI
    • IEEE 802.15.4 for low rate personal area networks
    • ISO 13374, MIMOSA OSA-CBM and OSA - EAI for Mapping, Extraction and Analysis of Legacy DB, Configurable Diagnosis, Configurable Prognosis, Prescriptive Analytics for Proactive Decision Making
    • IEC 60812 FMEA and FMECA for Maintenance Actions Parametrization and Management interface
    • EN 13306 for common maintenance terminology
    • ISO 17359 for condition monitoring and diagnostics on machine
    • ISO 13373 for vibration monitoring, ISO 18435, ISO 10303, ISO 15926 for interoperability
    • ISO 14224 for maintenance data in oil and gas
      Comment:

      Open Platform Communication Unified Architecture (OPC-UA) is considered for UPTIME platform and for modular edge data collection and diagnosis of UPTIME_SENSE component.

      Comment:

      IEEE 802.15.4 for low rate personal area networks.