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1 s2.0 S000785060760033X Main PDF
1 s2.0 S000785060760033X Main PDF
S. Takata1 (1), F. Kimura2 (1), F.J.A.M. van Houten3 (1), E. Westkmper4 (1)
M. Shpitalni5 (1), D. Ceglarek6 (2), J. Lee7
1
Waseda University, Japan, 2The University of Tokyo, Japan,
3
University of Twente, the Netherlands, 4Fraunhofer IPA, Germany, 5Technion, Israel,
6
University of Wisconsin-Madison, USA, 7University of Wisconsin-Milwaukee, USA
Abstract
As attention to environmental problems grows, product life cycle management is becoming a crucial issue in
realizing a sustainable society. Our objective is to provide the functions necessary for such a society while
minimizing material and energy consumption. From this viewpoint, we should redefine the role of maintenance
as a prime method for life cycle management. In this paper, we first discuss the changing role of maintenance
from the perspective of life cycle management. Then, we present a maintenance framework that shows
management cycles of maintenance activities during the product life cycle. According to this framework, we
identify technical issues of maintenance and discuss the advances of technologies supporting the change in
the role of maintenance.
Keywords:
Maintenance, Life Cycle Management
1 INTRODUCTION
Everyone agrees that maintenance is a necessity.
Nevertheless, maintenance has a negative image and is
sometimes regarded as a necessary evil. But as the
paradigm of manufacturing shift towards realizing a
sustainable society, we should also begin to recognize the
changing role of maintenance. The goal of manufacturing
is no longer to produce products in an efficient way, but
rather to provide the functions needed by society while
minimizing material and energy consumption. Product life
cycle management is becoming a crucial issue in order to
achieve this goal. In this context, the role of maintenance
should be redefined as an essential means for life cycle
management. Maintenance is the most efficient way to
keep the functional level of a product above the level
required from the viewpoint of environmental impact.
Traditionally, the scope of maintenance activities has been
limited to the operation phase. In considering the role of
maintenance in life cycle management, however, we
should be aware that there are close relationships between
maintenance activities and those in other phases of
product life cycle, such as the design, production, and end
of life phases. These relations create the necessity for
integration in terms of technologies as well as information
throughout the products life cycle so as to perform
effective maintenance. Hence, we should investigate
maintenance technologies more extensively in connection
with, for example, design technologies such as product
modeling and digital engineering.
Changing the role of maintenance could also affect the
business models of manufacturing companies. Attention to
maintenance could facilitate the transformation of
businesses from product providers to service providers,
with maintenance being a major service.
In this paper, we first discuss life cycle management for
closed-loop manufacturing, which could be an essential
means for realizing a sustainable society, and the
changing role of maintenance from the perspective of life
cycle management. Then, we present a maintenance
Part
maker
Product
maker
Raw
material
supplier
Material
maker
Seller
In-house reuse
User
In-house
maintainer
Product
reuse
Product
recovery
center
Part
reuse
Closed loop
material recycle
Part
recovery
center
Material
recovery
center
Recovered
material
user
Open loop
material
recycle
Oilificator
refiner
Metal
Collection
center
Dismantling
/Separation
Recycling
center
Oil
Shredding
plant
Shredder dust
Thermal
energy
collector
Energy
recovery
(energy, CO2 )
Landfill
Final
disposer
Functional
level
required
functional
level
Upgrade
Breakdown
Preventive
maintenance maintenance
Improvement
Initial
Functional
malfunction degradation
Failure
Time
Figure 2: Maintenance activities.
enhance the eco-efficiency [7] of the product life cycle as
explained above. We, therefore, use the term life cycle
maintenance to stress its role from the perspective of life
cycle management.
As previously mentioned, there are two reasons why it is
necessary to control the conditions of products: changes in
the condition of products due to deterioration, and the
changing needs of customers or of society. These changes
generate gaps between the required function and the
realized function. Maintenance is executed to compensate
these gaps by means of treatment or upgrading, as shown
in Figure 2. For this purpose, maintenance should involve
the following activities.
1. Maintainability design:
Improving design based on evaluating maintainability in
the product development phase and providing the
design data for maintenance strategy planning and
maintenance task control.
2. Maintenance strategy planning:
Selecting a maintenance strategy appropriate to each
part of the product.
3. Maintenance task control:
Planning and executing the maintenance tasks based
on the selected strategy.
4. Evaluation of maintenance results:
Evaluating the results of maintenance to determine
whether the maintenance strategy planning and
maintenance task control are appropriate.
5. Improvement of maintenance and products:
Improving maintenance task control, maintenance
strategy planning, and even product design based on
the evaluation of maintenance results.
6. Dismantling planning and execution:
Planning and execution of dismantling at the end of the
product life cycle.
Development
Design/
improvement
and
Production/
modification
Corrective
maintenance
3rd loop
Operation
Maintenance
strategy planning
Design data
and
Production
record
Deterioration
/failure
evaluation
Failure
effects
evaluation
Effectiveness
evaluation of maintenance
technologies
Maintenance
strategy
Revision of
maintenance
Maintenance
task
planning
Inspection
/monitoring
/diagnosis
Evaluation of
maintenance
results
Maintenance
task execution
2nd loop
1st loop
criteria for
providing
treatment
time
condition
detection of breakdown
detection of symptom
analysis of trend
opportunity of
maintenance
task execution
(inspection/monitoring
diagnosis/treatment)
during operation
during stoppage
when disassembled
type of treatment
servicing
repair
replacement
design improvement
Technological evaluation
Structure and
characteristics of
facilities
Available
maintenance
technologies
Environmental
conditions
Operational
conditions
Managerial
features of
facilities
Evaluation of deterioration
/failure characteristics
Evaluation of applicability of
maintenance technologies
Managerial evaluation
Evaluation of
failure effects
Evaluation of features
of facilities
Selection of
maintenance
strategy
Normal state
N
Symptomatic
State
D
start
start
setting
setting the
the goal
goal of
of maintenance
maintenance
Detecton
limit
Functional
limit
t0
tD
evaluation
evaluation of
of failure
failure
effects
effects
tF
selection
selection of
of technically
technically
feasible
feasible strategies
strategies
selection
selection of
of maintenance
maintenance strategy
strategy
of
of each
each component
component
evaluation
evaluation of
of risk
risk of
of failures
failures
(likelihood*
(likelihood* expected
expected loss)
loss)
no.
the
the goal
goal is
is achievable?
achievable?
yes.
end
end
design for
maintenance
maintenance
planning
technologies
sensor, signal
processing,
chemical analysis
failure analysis
failure physics
deterioration
evaluation, life
span
evaluation,
FMEA, FTA
deterioration
evaluation,
residual life
evaluation,
FMEA, FTA
artificial
intelligence,
knowledge
management
model-based
technologies
reliability
engineering,
inspection/
monitoring/
diagnosis
inspection/
monitoring/
diagnosis
trend analysis
monitoring/
diagnosis/
prognosis
deterioration
and failure
simulation
reliability
design
risk management
network,
database.
deterioration
and failure
mechanism
database
design
methodologies
DfX
(accessibility,
assemblability,
disassemblabil
ity),
tolerancing
deterioration
and failure
simulation
RCM
model-based
monitoring/
diagnosis
RBM
RBI
deterioration
and failure
mechanism
database
remote
monitoring,
remote
diagnosis
end of life
treatment
life cycle
management
condition
diagnosis
deterioration
evaluation,
residual life
evaluation
selfmaintenance
operation
support
system (ES)
operation
support
system (VR)
malfunction
data collection
system
operation
support system
(VR)
residual life
evaluation
tele-service
MP data
management
life cycle
maintenance
data
management
maintainability/ upgrade
serviceability
automation,
robotics
organizational
and human
factors, method
engineering
middle of life
treatment
TPM
environmental
management
costing
maintenance
robot
automated
disassembly
TPM
operation
support
system
operation
support system
LCA
LCC
The study of systematic approaches to maintenance
strategy planning is, however, a relatively new area of
research. The most well known methodology for this
purpose is RCM. It was developed in the field of aircraft
maintenance in the late 1970s. Recently it has been
applied to other areas, such as nuclear power plants and
various manufacturing plants. RCM provides a systematic
procedure for maintenance strategy planning based on a
logic tree analysis, in which effects of failure are first
categorized and then effectiveness of maintenance actions
are evaluated based on the procedures given according to
the categories of effects.
In addition to RCM, Risk-Based Inspection (RBI) or RiskBased Maintenance (RBM) has attracted attention in
recent years as a systematic method for maintenance
strategy planning, especially in the area of nuclear power
item
sensing
sensing
processing
processing
judging
judging
information
for criteria
Take account of
- Inertia force
- Gravity
- Load applied
on tool
Stress
evaluation
Robotic
model
Part stress
evaluation
Task
descriptions
Wear
prediction
Contact pressure
Sliding Length
Wear
model
Functional
evaluation
Positioning
error of tool
Wear of gears
Usage Mode
Input Order
Elevator
State
Observable
State Data
State Model
Failure
Performance
Model
(State -> Pfrm.)
Failure Model
(Random)
Service
Engineer
Monitoring Data
Elevator State
Load Model
(Load -> State)
Performance
Requirement/
Usage Mode
Monitoring
Unit
Observable
Pfrm. Data
Maintenance
Execution
Model
State
Maintenance Necessity
Regular
Maintenance
Scheule
Preventive
Maintenance
Order
Observable
Failure
Data
Corrective Maintenance Order
Inherent
Inherent
Imperfection
Imperfection
Manufacturing
Manufacturing
Systems
Systems
Unavoidable
Unavoidable
Deterioration
Deterioration
Cost
Cost
Maintenance
Maintenance
(Reactive,
(Reactive, Preventive,
Preventive,
Predictive,
Predictive, etc.)
etc.)
Degradation
Process
Equipment or
Process
Expert
Knowledge
Model
3Ws
When?
Why?
What?
Assessment
Embedded
Sensors
Watchdog
Agent
Forecasting
Degradation
Information
Prognostics
Device-toBusiness(D2B)
5.6 Self-maintenance
Nowadays, most products have self-diagnostic functions
executable by a build-in microprocessor. Although these
functions are regarded as a kind of self-maintenance, the
concept of self-maintenance discussed in this section
includes not only self-diagnosis but also self-repair and
self-evolution. A self-maintenance machine should be
equipped with a control and reasoning processor, sensors,
and actuators to perform these tasks. In contrast to
biological systems, however, it is difficult for a mechanical
system to repair itself physically. Instead, the repair is
carried out functionally. If a failure occurs, the product
autonomously recognizes the failure through its self-
Life cycle
simulation
Maintenance Maintenance
task
strategy
management
planning
Prognosis/
Diagnosis
CAD
Diagnosis
Maintenance
data
management
Operation
Record
Inter-net
Cases of
other
industry
CAE
LCS
Maintenance
Record
Intra-net
Facility
Model
Extra-net
Knowledge
mgmt.
Tele-operation
Tele-service
Tele-maintenance
Inspection Co.
Machine
vender
Research
Ins.
Public
DB
Elec.
catalog
Controller
vender
Maintenance
service
Maintenance technology DB
Deterioration/failure physics DB
Deterioration/failure cases
Product directory
Service directory
Manufacturing Facilities
Maintenance vehicle
Remote maintenance
Remote monitoring and diagnosis was discussed
considerably in the 1970s, when the technology for data
transmission via telephone line was first developed.
Although many machine tool manufacturers offered remote
maintenance service at that time, this type of service did
not become popular due to the immaturity of the
technology. Recent developments in Internet and wireless
communication technologies, however, have enabled
remote maintenance to be put to practical use.
Web-based maintenance service
Internet technology makes it possible to provide various
maintenance services other than remote monitoring and
diagnosis via networks. Emphasis is placed on providing
entire services for life cycle management via a network,
such as deterioration and failure analysis, residual life
estimation, maintenance strategy planning, maintenance
task management, end-of-life treatment and life cycle data
management [78-81]. Figure 14 illustrates the concept of a
network-based maintenance system. An intelligent
maintenance service platform is proposed to enable easy
implementation of a web-based maintenance service
system. The platform consists of five layers: interface
layer, data transformation layer, data transfer layer,
intelligent informatics tools, and synchronization module
[82].
6 SUMMARY
In this paper, we have discussed the changing role of
maintenance from the perspective of life cycle
management. Although the critical role of maintenance
within automated factories was pointed out by Yoshikawa a
quarter of a century ago [83], maintenance has long had a
negative image. However, in view of sustainable
manufacturing, we should redefine the role of maintenance
as a prime method for life cycle management whose
objective is to provide society with required functions
through products while minimizing material and energy
consumption.
Though an enormous number of works have focused upon
maintenance as a whole, they are dispersed across
various areas and are not yet systematized. We, therefore,
have proposed a maintenance framework that could help
us discuss maintenance technologies from various areas
on the same table.
Recent advancements in information and communication
technologies could also facilitate the integration of
maintenance activities. There are many possibilities for
making use of technologies such as digital modeling and
web-based technologies to improve maintenance
effectiveness.
AKNOWLEGEMENTS
The authors would like to acknowledge the great
contribution of Prof. T. Tomiyama (Delft University of
Technology, The Netherlands), Prof. G. Seliger (Technical
University of Berlin, Germany), Prof. L. Monostori
(Hungarian Academy of Sciences, Hungary), Prof. V. D.
Majstorovic (University of Beograd, Serbia and
Montenegro), and Prof. J. Ni (University of Michigan,
U.S.A.).
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