Maintenance Decision Support for Manufacturing Systems Based on the Minimization of the Life Cycle Cost
Abstract: The reduction of the overall Life Cycle Costs (LCC) is a key issue in manufacturing sector. Among the various contributions to LCC an important part is due to Reliability and Maintainability (R&M) issues and therefore a substantial reduction in LCC can be achieved by a conscious decisions and planning. Besides the failure and repair characteristics, the R&M related costs vary according to the maintenance strategy and policy selected for each components that form the manufacturing system. The aim of this paper is to describe a mathematical model that takes into account the R&M related fraction of the LCC in order to compare scenarios in which different maintenance strategies and policies are applied on the components of manufacturing systems. The calculations cover three policy possibilities: internal crew, external service (on-demand) and external service (annual contract). Both scheduled (preventive maintenance, inspection-based maintenance) and unscheduled (corrective maintenance, condition monitoring) strategies are considered. On the basis of the proposed formulae, optimization is carried out with a view to find the best solution in economical aspect. Furthermore, the method takes into account the possibility of clustering the scheduled interventions with the intention of reaching a predefined availability constraint while keeping the costs as low as possible. The paper presents the results of the European FP7 research project EASE-R3 where a specific maintenance planning software tool is being developed implementing the methodologies outlined above.
The video demonstrates the usage of the DDSS (Decommissioning Decision Support System). The aim of this application is to select the optimal end-of-life strategies with respect to the life cycle cost and the environmental stressors.
The video demonstrates the usage of the RDSS (Repair Decision Support System). The aim of this application is to select the most cost-effective maintenance strategies and policies for the components of a machine tool.
The video shows the Integrated framework developed on the EASE-R3 project for a cost-effective and easy Repair,Renovation and Re-use of machine tools within modern Factory. This framework is oriented both to SME and large OEM/end-users, and covering the entire life cycle of the system (from design stage through operative life).
This video overviews the development of a model with GUI to simulate the wire-cutting dynamics. This user-friendly GUI enables the user to input the wire-cutting process parameters. It then performs a static and dynamics simulations yielding the cutting forces, tension, pressure, vibrations and sound… as they evolve during the process.
The video shows a software program integrated in the tablet surface which allow the machine operator or maintenance personal to perform maintenance and remanufacturing tasks using VR and AR programs.
The video shows a process monitoring system of a broaching tool thanks to the integration of a force measuring system. A program integrated in the machine is able to anticipate possible wear problems of the broach.
The video shows the concept and implementation of the dynamic error detection module (DEDM), a newly conceived multi-directional laser measurement system that can determine and monitor the geometric errors of the axis of a machining centre on which it is installed.
The video shows the concept and implementation of the smart thermal compensation module (STCM), which is a method of cost-effectively improving the accuracy of a machine tool by reducing its responsiveness to thermal inputs.
EASE-R3 considers standardization activities as an important instrument to enhance the transfer of research results into practice and on the market even after the end of the project. EASE-R3 is therefore delighted to be invited to attend the meeting of ISO/TC 39/SC 2 Test conditions for metal cutting machine tools on May 11th in order to discuss some of the research results with the experts of the ISO/TC subcommittee. The meeting will be held in Stuttgart at the Institute of Machine Tools at University Stuttgart.