Periodic Reporting for period 1 - Z-BRE4K (Strategies and Predictive Maintenance models wrapped around physical systems for Zero-unexpected-Breakdowns and increased operating life of Factories)

At present, maintenance in general and predictive maintenance strategies in particular are facing significant challenges in dealing with the evolution of the equipment, instrumentation and manufacturing processes they support. The volatility of market demands intensified by...


At present, maintenance in general and predictive maintenance strategies in particular are facing significant challenges in dealing with the evolution of the equipment, instrumentation and manufacturing processes they support. The volatility of market demands intensified by the manufacturing trends of mass customisation and individualisation combined with pressure to harness production costs imply that manufacturing configurations need to change more frequently and dynamically. So, preventive maintenance strategies designed for traditional highly repetitive and stable mass production processes based on predefined components and machine behaviour models are no longer valid and more adaptive and responsive (predictive-prescriptive) maintenance strategies are needed.

The Z-BRE4K solution comprises the introduction of eight (8) scalable strategies at component, machine and system level targeting (i) the prediction occurrence of failure based on evidences (Z-PREDICT), (ii) the early detection of current or emerging failure (Z-DIAGNOSE), (iii) the prevention of failure occurrence, building up, or even propagation within the production system (Z-PREVENT), (iv) the estimation of the remaining useful life (RUL) of assets (Z-ESTIMATE), (v) the management of the aforementioned strategies through event modelling, KPI (key performance indicators) monitoring and real-time decision support (Z-MANAGE), (vi) the replacement, reconfiguration, re-use, retirement, and recycling of components/assets (Z-REMEDIATE), (vii) synchronizing remedy actions, production planning and logistics (Z-SYNCHRONISE), (viii) while preserve the safety, health, and comfort of the human workers (Z-SAFETY).

The main objective of the Z-BRE4K concept is to provide new solutions addressing the needs for predictive maintenance manufacturing requirement, bring innovative products to the market, face future challenges regarding standards and legislation, and spread the knowledge to as many sectors of the European manufacturing industry as possible.

Manufacturing enterprises are pushed to take ?local? actions: thinking globally but acting and staying economically compatible within the local (regional and national) context. In order to achieve high precision manufacturing of complex products, there has to be a fundamental rethink on how to improve the operation of machines and improved controls. The improvement should not only concern the individual machines as isolated islands but encompass the totality of production process as a system of interrelated elements that seek to maximise efficiency, productivity, customer satisfaction; whilst at the same time eliminate waste and excess inventory.

Work Performed

Main results achieved so far:

- User requirements, end user scenarios, Z-BRE4K general architecture and how it will be adapted to every different use case have been defined.

- An operating system based on a combination of Open Source frameworks and reference architectures including AUTOWARE and IDS RA has been described.
- IDS connectors have been also developed in the WP2, even though they will be deployed in the scope of WP5.
- High-fidelity machine simulators have been developed by modelling the failure modes.
- A Smart Object Network (SoN) has been developed to allow data acquisition in real time from different sensors/devices/machine and data aggregation, converting the data into value and sharing it through the IDS connectors.
- Development of 2 CECM components for the GESTAMP use case for Forming and Welding stations.

- A semantic model and its corresponding hierarchy as a common reference model for annotation and description of knowledge to represent manufacturing system performance through identification of all the entities of production assets, products and processes in the domain of maintenance has been designed.
- The FMECA component has been developed and its functionality has been tested by all the three end users.

- Analysis of existing predictive maintenance strategies and the SoA on the industrial maintenance strategies and policies, definition and alignment of Z-Strategies with the Z-BRE4K use case scenarios, and collection of AS-IS maintenance strategies and policies from Z-BRE4K end-users.

- A 1st Interim Plan for the Exploitation and Dissemination of Results has been defined.
- Creation of Project Website and Material for dissemination of the project, namely: project logo, templates for public presentations, roll-up and brochure.
- Dissemination activities have been also carried out by several partners in different events and congresses worldwide.

It should be also mentioned that continuously monitoring of both Project and Business Risks in WP1 and WP7, respectively.


18 deliverables have been submitted so far. Just a few deliverables have suffered minor modifications and/or delays, that have been properly communicated to and approved by the Project Officer. That is the case of D1.2 (2-month delay), D2.2 (1-month delay), D5.1 (1st version on M15 and updated version by M18), D8.4 (Updated versions by M18 and M30 will be submitted substituting the previous ones).


Milestones MS1, MS2 and MS3 were accomplished in this period. In the case of MS7, it should be noted that is has been partially reached since the consortium is still working and improving the deployment environment and the communication of the ML/Prediction components as they are close to the production assets.


Z-BRE4K will advance SOTA through an integrated approach leveraging IIoT and predictive analytics, in combination with Enterprise Asset Management (EAM) and Decision Support System (DSS) functionality, for the benefit of significantly improved maintainability.

To this end, knowledge and alarms from the detection and prediction layers will be exploited in order to reconfigure system parameters and readjust operations and processes, prevent unexpected breakdowns, repair/replace/reuse of shopfloor resources, exchange data knowledge and alarms with higher level management systems for scheduling maintenance and re-adapting production scheduling. Dedicated modules will be included within our integrated DSS for:

- Recommendations Provision: It will leverage knowledge and alarms from the Networked Machine and Product Levels technologies (predictive modelling, RUL estimation, FMs and Effects, KM, etc.) and provide recommendations for improving maintainability and operational efficiency at the shopfloor.
- Maintenance scheduling: Planning of maintenance processes and provision of routing output with tasks steps and human/material prerequisites, timing of activities, etc.

Moreover, Z-BRE4K will be a pioneer in this area, advancing the SOTA by elaborating KRIs and Risk Assessment approaches in the maintenance field of industrial manufacturing. Z-BRE4K work will be based on international standard IEC6081231, and metrics will be defined to measure each KRI with multiple KRIs being associated to a single or multiple risks.

The impact of Z-BRE4K to the European manufacturing industry, but also the society itself, can be summarised in the following (with a horizon of 4 years after project ends): (i) increase of the in-service efficiency by 24%, (ii) reduced accidents, (iii) increased Verification according to objectives, (iv) 400 new jobs created and (v) over 42 MEUR ROI for the consortium.
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