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IFAC PapersOnLine 55-19 (2022) 187–192
Combining
Combining Design
Design Thinking
Thinking and
and Agile
Agile to
to
Combining
Combining
Combining
Implement Design
Design
Design
Condition Thinking
Thinking
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Implement
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Design
Condition Monitoring
Thinking and
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System:
Implement
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A Case Condition
Condition
Study on Monitoring
Monitoring
Paper Press System:
System:
Bearings
A
A Case
Case Study
Implement
Study on
on Paper
Condition Press Bearings
Monitoring
Paper Press System:
Bearings
A
A Case
Case Study
Study on
on Paper
Paper Press
Press Bearings
Bearings
A Case Study on Paper Press Bearings
René ∗
René Vinicio
∗
Vinicio Sánchez
Sánchez ∗ Julio Fernando Siguencia ∗
∗ ∗ Julio Fernando∗ Siguencia ∗ ∗
René
Mauricio
René Vinicio
Villacı́s
Vinicio Sánchez
Diego
Sánchez
∗ ∗ Julio
∗ Cabrera
Julio Fernando
∗ Mariela
Fernando Siguencia
Cerrada
Siguencia ∗
∗ ∗
Mauricio
René Villacı́s
Vinicio Diego
Sánchez
∗ Cabrera
Julio Fernando
∗ ∗ Mariela Cerrada
Siguencia ∗
Mauricio
René
Mauricio Villacı́s
Vinicio
Villacı́s Diego
Fernando
∗
Sánchez
∗ Diego ∗ Cabrera
Heredia
Julio
Cabrera ∗
Fernando
∗ Mariela
∗Mariela Cerrada
Siguencia
Cerrada ∗ ∗
Mauricio Villacı́sFernando ∗ Diego Cabrera
Fernando
Heredia
Heredia ∗ ∗∗
Mariela Cerrada ∗∗
Mauricio Villacı́sFernando Diego Cabrera
Fernando Heredia ∗∗Mariela Cerrada
Heredia
∗
∗ Universidad Politécnica Salesiana,
Fernando Cuenca, CO 010202 Ecuador
Heredia
∗ Universidad Politécnica Salesiana, Cuenca, CO 010202 Ecuador
∗ Universidad Politécnica
∗ Universidad Politécnica (e-mail: Salesiana, Cuenca,
rsanchezl@ups.edu.ec) CO 010202 Ecuador
∗ Universidad Politécnica
(e-mail: Salesiana, Cuenca,
Cuenca, CO
rsanchezl@ups.edu.ec)
Salesiana, CO 010202
010202 Ecuador
Ecuador
Universidad Politécnica(e-mail:
(e-mail: rsanchezl@ups.edu.ec)
Salesiana, Cuenca, CO 010202 Ecuador
(e-mail: rsanchezl@ups.edu.ec)
rsanchezl@ups.edu.ec)
Abstract: (e-mail: rsanchezl@ups.edu.ec)
Abstract:
Abstract:
Nowadays,
Abstract: technologies
Nowadays,
Abstract: technologies and and strategies
strategies to to bring
bring processes
processes toward
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Abstract:
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articlein each
as itthemeeting. BY-NC-ND
CCpossible license
Copyright
design
industry
industry © 2022was
thinking
personnel
personnel and
andAuthors.
fundamental
to
to have
haveThis is an
for open
the
materialized
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(https://creativecommons.org
industry
Keywords:
Keywords:
personnel
Condition
Condition monitoring, /licenses/by-nc-nd/4.0/)
and to have
monitoring,
materialized
Design
Design Thinking,
progress in each
Thinking, Agile,
Agile, Paper
meeting.
Paper Industry,
Industry, Bearing
Bearing Fault,
Fault,
Keywords:
Industry
Keywords:4.0. Condition
4.0. monitoring,
Condition monitoring,
monitoring, Design Design Thinking,
Design Thinking, Agile,
Thinking, Agile, Paper
Agile, Paper Industry,
Paper Industry, Bearing
Industry, Bearing Fault,
Bearing Fault,
Fault,
Industry
Keywords: Condition
Industry
Keywords:
Industry 4.0. 4.0.
Condition
4.0. monitoring, Design Thinking, Agile, Paper Industry, Bearing Fault,
Industry
Industry 1. 4.0.
INTRODUCTION system.
1. INTRODUCTION system. Although there are commercial vibration
Although there are commercial vibration moni- moni-
1. INTRODUCTION system.
toring Although
systems, it there
is not are
easy commercial
for industries vibration
to moni-
1. INTRODUCTION
1. INTRODUCTION system.
toring
system. Although
systems,
Although it isthere are
not easy
there are commercial
for industries
commercial to implement
vibration
vibration moni-
implement
moni-
The paper industry 1. seeks to
INTRODUCTION reduce costs, including costs toring
them;
system. systems,
among
Although it
the is not
causes
there easy
may
are for
be:industries
staff
commercial to
resistance
vibration implement
to the
moni-
The paper industry seeks to reduce costs, including costs toring them;
toring
them;
entry
systems,
among
systems,
among
of new
it
the
it
the
is not
causes
is not
causes
technology
easy
mayfor
easy
may
into
be:industries
for
be:
their
staff resistance
industries
staff
processes,
to
to
resistance
implement
to
implement
lack to
of
the
the
staff
The
The paper
associated
paper industry
with
industry seeks
unplanned
seeks to
to reduce
maintenance
reduce costs,
costs, including
downtime;
including costs
there-
costs toring
them;
entry
them; systems,
among
of new
among it
the is
technology
the not
causes
causes easy
may
into
may for
be:
their
be:industries
staff to
resistance
processes,
staff resistance implement
lack to
of
to the
staff
the
associated
The paper with
industry unplanned
seeks tomaintenance
reduce costs,downtime;
including there-
costs entry
training,of new
and technology
distrust of into
the their
technology processes,
to be lack of
implementedstaff
associated
fore,
The paper
associated with
conditionindustry unplanned
monitoring
with monitoring seeks tomaintenance
(CM)
unplanned maintenance reduce provides
maintenance costs,downtime;
valuable
including
downtime; there-
infor-
costs
there- them;
entry among
of new the causes
technology may
into be:
their staff resistance
processes, lack to
of the
staff
fore, condition
associated with unplanned (CM) provides valuable there-
downtime; infor- training,
entry
training,
(Birkel of et
and distrust
new
and
al., technology
distrust
2019;
of the
of
Horvath into
the
technology
their
technology
and Szabo,
to be implemented
processes,
to
2019;be lack of
implemented
Sievers staff
et al.,
fore,
mation condition
associated
fore, to make
with
condition monitoring
timely
unplanned
monitoring (CM)
maintenance provides
maintenance
(CM) provides valuable
decisions
downtime;
valuableand infor-
avoid
there-
infor- entry
training,
(Birkel of etnew
and
al., technology
distrust
2019; of
Horvath into
the their
technology
and processes,
Szabo, to
2019;be lack of
implemented
Sievers staff
et al.,
mation
fore, to makemonitoring
condition timely maintenance (CM) provides decisions
valuable avoid training,
and infor- (Birkel
2021). et and
al., distrust
2019; of the and
Horvath technology
Szabo, to be Sievers
2019; implemented
et al.,
mation
unplanned
fore,
mation to make
condition
to downtime
make timely
monitoring
timely or maintenance
catastrophic
(CM)
maintenance decisions
damage
provides valuable
decisions and
and avoid
(Acernese
infor-
avoid training,
(Birkel
2021).
(Birkel et
et and
al.,
al., distrust
2019;
2019; of
Horvath
Horvath the technology
and
and Szabo,
Szabo, to
2019;
2019;be implemented
Sievers
Sievers et
et al.,
al.,
unplanned
mation downtime
to make timely or catastrophic
maintenance damage
decisions (Acernese
and avoid 2021).
unplanned
et al.,
mation
unplanned2020;
to downtime
make Ali
downtime and
timely or catastrophic
Abdelhadi,
maintenance
or catastrophic 2022).
catastrophic damage
decisions (Acernese
and
damage (Acernese avoid
(Acernese This (Birkel
2021).
2021). et
paper al., 2019;
presents Horvath
a case and Szabo,
study that2019; Sievers
combines et al.,
agile
et al., 2020;downtime
unplanned Ali and Abdelhadi,
or 2022). damage This paper presents a case study that combines agile
et
et al.,
unplanned
al., 2020;
2020; Ali
downtime
Ali and
and Abdelhadi,
or 2022).
catastrophic
Abdelhadi, 2022). damage (Acernese 2021).
This
In
et
In the
al., market,
the 2020;
market, Alithere are
are different
and Abdelhadi,
there commercial
commercial systems
different2022). systems for This paper
for methodologies
This paper presents
methodologies
paper
and
and design
presents
presents
aa case
design case
a case
study
thinking
study to
thinking
study
that
that
to
that
combines
implement
combinesa
implement
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agile
con-
agile
a agile
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et al.,
In the 2020;
monitoringmarket, Alithere
the and Abdelhadi,
condition are different
of 2022).
commercial
parameters such assystems
vibration,for methodologies
dition
This monitoring
paper and
presents design
system a on
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paper
study to
press
that implement
bearings.
combines a con-
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monitoring
In market, there
the there
condition are different
are different
of parameters commercial systems
such assystems
commercial vibration,for methodologies
for dition monitoring
methodologies and
and design
system
design thinking
onthinking
paper press to
to implement
bearings. a con-
implement a con-
monitoring the condition of dition monitoring system on paper press bearings.
temperature,
In the market,
monitoring
temperature,
monitoring thecurrent,
the there
condition
current,
condition
among
are
amongof parameters
of
others.
different
parameters
others.
parameters
such
such as
Vibration
commercial
Vibration
such as
vibration,
condition
assystems
vibration,
condition
vibration,for methodologies
dition
The
dition monitoring
condition
monitoring andsystem
designon
monitoring
system thinking
paper
system
on paper on to
press implement
paper
press bearings.
press
bearings. a con-
bearings
temperature,
monitoring current,
systems among
have ofbeen others.
the Vibration condition The condition monitoring system
paperon paper press bearings
monitoring
temperature,
monitoring
temperature, the condition
current,
systems
current, among
have
among been the most
parameters
others.
others. mostsuch developed
Vibration as vibration,
developed
Vibration
due
due dition
condition
condition The
was
The
was
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developed
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within
monitoring
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the
on
system
framework
system
framework
on
on
press
paper
paper of
of
bearings.
aapress bearings
cooperation
press bearings
cooperation
monitoring
to their
temperature,
monitoring abilitysystems
systemsto
current, have
detect
among
have been
most
been the
the
others.
the most
failures, developed
Vibration
most especially
developed due
condition
duein The
was
projectcondition
developed
between monitoring
within
the the system
university, framework
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paper of apress
industry, bearings
cooperation
and
to
to
their
monitoring
their
bearings
monitoring
to their
ability
ability
(Liu
their ability
ability
systems
et
systems
to
to
al.,
to
detect
have
detect
2022).
have
detect
most
been
most
been
most the
the
the
the
the
failures,
most
failures,
most
the failures,
especially
developed
especially
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failures, especially
especially in
due
due
in
in The
was
project
was
in Ecuadorian
condition
developed
between
developed monitoring
within
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within the
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university, framework
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frameworkon paper
paper of
of a
apress
industry, and the
bearings
cooperation
cooperationthe
bearings
to (Liu et to al.,detect
2022).most project
was
project between
developed
between the
Corporation
within
the university,
for
the
university, the the
framework
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Development
paper industry,
of a
industry, of and
cooperation
and the
Research
the
bearings
to their
bearings (Liu
(Liu et
ability et toal., 2022).
al.,detect
2022). most themonitoring
failures, especially Ecuadorian
project
in project betweenCorporation
the for
university, the theDevelopment
paper industry, of Research
and the
The implementation
bearings (Liu et al., of
2022). condition systems in Ecuadorian
and Academia
Ecuadorian betweenCorporation
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the
Corporation for
The
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objective
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2405-8963University.
Peer review under responsibility of International Federation of Automatic Control.
10.1016/j.ifacol.2022.09.205
188 René Vinicio Sánchez et al. / IFAC PapersOnLine 55-19 (2022) 187–192
2. BACKGROUND
2.1 Design thinking
When implementing a project in an industry, especially
a project involving technology, there is often resistance
among the personnel involved in the project because the
requirements of the client and the end user are often not
adequately satisfied (Chaurey et al., 2021; Celik and Kan-
demir, 2017). Design thinking helps in the development of
innovative products and services focused on user needs and
desires, while ensuring technical feasibility and economic
viability (Przybilla et al., 2018; Sánchez-Gordón et al.,
2021; Liu and Lu, 2020). The design thinking methodology
was initially used only by designers, however, due to the
diversity of tools and methods it employs, it has proven
to help manage complex problems. This is due to its
collaborative and user-centered approach, which allows the
discovery of hidden needs and the development of desirable
and achievable solutions (Lahiri et al., 2021; Rozante de
Paula et al., 2020). In the literature, there are few cases of
application of design thinking in the field of maintenance
(Teperi et al., 2020; Vrana and Singh, 2021). The articles
emphasize the advantage of design thinking to empathize,
concreteness, cooperation in the outlining of stakeholder
strategies.
2.2 Design thinking and its combination with agile
methodologies
In the development of projects, design thinking combined
with agile methodologies has proven to be very success-
ful in the IT industry, due to empathy and permanent
communication between the development team, clients
and end users to address the solution of problems and
implementation of projects (Pereira and de F.S.M. Russo,
2018; Sánchez-Gordón et al., 2021). In the work presented
by Henreaux et al. (2021) they present a case study of the
automotive industry where they combined agile method-
ologies to iterate the five phases of design thinking, this
with the objective of test-and-refine prototypes for road
sign assistance and adaptive cruise-control technologies.
The case study allowed them to identify some advantages
such as efficiency in getting design ideas off the ground
or producing innovations in a reasonable timeframe. How-
ever, to further increase the efficiency of the organization,
the team must work with clear specific objectives and
realistic timelines. Also include a strategic leader who can
make decisions.
3. METHODOLOGY
The implementation of the condition monitoring system
was developed in six design sprints, each sprint corre-
sponding to a design thinking process phase. The following
is a general presentation of how the implementation was
developed.
3.1 Empathize
This phase begins with a meeting to present the work
teams. Three teachers and four engineers participated for
GIDTEC; initially only the maintenance department staff
participated for the industry, but after the first meeting
it was agreed to include the Information Technology (IT)
department. For a better understanding and immersion
in the problem to be solved, the following activities were
carried out by GIDTEC:
• Visit all paper production processes.
• Reviewing the maintenance histories of the press,
especially the bearings.
• Measurement of the vibration levels of the press
bearings, this was done with GIDTEC’s portable
equipment.
• Interviews with maintenance and IT department
staffs.
• Review of vibration level histories carried out by an
external industry.
• Meetings with work teams via videoconference.
• Problem tree.
Results of activities:
• So far, the maintenance department has performed
the bearing changes when suggested by the external
industry that performs the vibration measurements;
however, these measurements are performed every six
months, and they are not timely to avoid failures,
which has led to the shutdown of the presses as
evidenced in the maintenance reports.
• The head of the maintenance department requires
that the equipment be compatible with the equipment
they have installed, especially that it has communi-
cation with the SCADA system.
• The head of maintenance requires that the sensors be
connected by cable and that everything be processed
on a local computer.
• The maintenance department has already had pro-
posals from different suppliers of condition monitor-
ing systems, but they have not been able to imple-
ment them due to equipment compatibility problems
and lack of confidence in the operation of this type of
system.
• The vibration measurement must be on the three axes
of each bearing.
• The head of the IT department states that the sys-
tems to be implemented must comply with cyberse-
curity protocols.
• The working environment is above 60 °C, with high
humidity and dirt.
3.2 Define
We used focus groups and in-depth interviews with the
maintenance manager, maintenance planner, lubricator,
and IT department staff for problem definition. The prob-
lem was defined as The need for a system that allows
detecting early failures in press bearings and satisfies the
requirements indicated in the results of the empathy stage.
3.3 Ideate
Based on the data collected in the previous two phases,
GIDTEC conducted a brainstorming workshop with the
IT and maintenance departments to develop possible solu-
tions and their characteristics. Several ideas were obtained
and refined into two, which are presented below:
 René Vinicio Sánchez et al. / IFAC PapersOnLine 55-19 (2022) 187–192 189
• Idea one: All sensors wired to the PLC for the
monitoring system to connect to the SCADA system.
• Idea two: Wireless sensors to communicate with the
SCADA system.
3.4 Prototype
This phase was divided into two stages because two
different resources were used to prototype the ideas.
(1) Stage one called schemes: It was decided in agree-
ment with the industry that the GIDTEC group
would contact and request six suppliers of condition
monitoring systems that meet the requirements and
needs collected in the previous phases. This decision
was adopted based on the industry’s requirement that
indicated in the ideation phase that the system to be
implemented should meet the characteristics to work
in industrial environments. Five suppliers submitted
bids and GIDTEC reviewed and verified that each
bid met the industry’s needs, then prototyped each
supplier’s solution and presented it to the industry’s
personnel. The scheme that met the industry’s needs
is illustrated in Figure 1. However, maintenance and
IT staffs indicated that they have doubts that it meets
their needs. For this reason, GIDTEC developed the
following stage, ”Stage two prototypes in the labora-
tory”.
(2) Stage two, prototype in the laboratory: In this
stage, GIDTEC implemented in the laboratory of the
University the sketch of Figure 1. The objective is
that industry personnel visit the laboratory and verify
that the wireless technology works in the laboratory
and communicates with the SCADA system. We also
made a video that can be seen at: Link 1.
Results of the prototypes: After the visit to the lab-
oratory, the heads of maintenance and the IT depart-
ment maintained the doubt about the wireless sensors and
their communication within the industry; they mentioned
that everything works well in the laboratory. Therefore,
GIDTEC proposed to test the equipment in the industry,
to which the industry agreed, but without allowing the use
of its internet network.
3.5 Test
This phase was divided into three stages.
(1) Planning and approval stage one: The mounting
points of the accelerometers on the presses and the
location of the communication elements were defined.
The maintenance personnel and the IT department
reviewed the planning and provided feedback for a
better location of the elements and safety of the
personnel who would perform the installation.
(2) Stage two, pilot commissioning: A two-week
schedule was made for the assembly of the elements
of figure 1, the entire assembly was carried out by the
industry’s personnel with the support of GIDTEC. At
this stage, two accelerometers and the communication
elements were put into operation, after which the
communication tests, data visualization and verifica-
tion of the vibration signal were carried out by com-
paring the signal with the manual measuring equip-
ment. The test results convinced the personnel of the
departments involved, so the industry authorized the
installation of the remaining ten sensors and dele-
gated a technician from the maintenance department
to manage the condition monitoring system.
(3) Stage three, testing by the industry: The dele-
gated technician of the maintenance department to-
gether with GIDTEC monitoring the vibration and
temperature signals of the bearings of the presses for
one month. At this stage during the monitoring, a vi-
bration signal trend was identified that indicated fail-
ure of the race of one of the bearings. The GIDTEC
proceeded to take measurements with portable equip-
ment to verify the trend, it also coincided that in that
same period the external industry that performed
the vibration analysis confirmed the failure, so the
maintenance department proceeded to replace the
bearing. After the replacement, a visual examination
verified that the bearing was indeed damaged, and
the maintenance technician noticed that the vibration
levels decreased.
The most interesting results of this phase were:
• The maintenance and IT managers decided that it
was not necessary to display the monitored signals
on the SCADA system.
• The wireless sensors were working properly in the
section to be installed and had the advantage of
quick mounting and dismounting at the time of any
maintenance task.
• Initially, the maintenance personnel were only inter-
ested in the vibration signal, but after testing with
the GIDTEC equipment that could monitor vibra-
tion and temperature, they decided that temperature
was a very useful measurement in their maintenance
processes.
3.6 Implement
The implementation was carried out in seven stages, which
are described below.
(1) Stage one: In this stage, GIDTEC made the request
to suppliers to submit their offers to the industry and
verified that the equipment offered by the suppliers
complied with the characteristics similar or superior
to the equipment used in the test phase.
(2) Stage two: Acquisition of equipment by the industry,
in this stage GIDTEC, supported with a matrix for
the selection of equipment for the industry to make
the decision on which supplier to buy.
(3) Stage three: Commissioning of the condition moni-
toring system equipment by industry personnel with
support from GIDTEC and the supplier.
190 René Vinicio Sánchez et al. / IFAC PapersOnLine 55-19 (2022) 187–192
Fig. 1. Architecture for an Intelligent Monitoring System in Industry.
(4) Stage four: Training on the condition monitoring
system to maintenance personnel and IT department.
(5) Stage five: Systematization by GIDTEC of all the
information and activities carried out during the
project.
(6) Stage six: Socialization of the systematized infor-
mation, the systematized information was sent to all
maintenance personnel and the IT department for
review. Then at the weekly meeting the summary
was presented, and the industry’s personnel asked for
more information to be added, which was done and
delivered to the departmental heads.
(7) Stage seven: Final closing meeting. At this meeting,
the legal documents indicating that the industry was
satisfied with the implemented system were signed. In
addition, GIDTEC conducted interviews to get their
point of view of the project implementation process.
4. OBSERVATIONS
The following are the main observations from the authors
as participant observers and from the heads of the main-
tenance and IT departments as clients.
4.1 Observations on behalf of the research
• This project was implemented between February and
August 2021 when we were still with limitations of
access by COVID-19 to the industry. The authors’
observations are presented below.
• The meetings during the first two months were held
every two weeks and virtually, with visits to the
industry to learn about the production process and
perform vibration measurements with the GIDTEC
equipment. In these visits, the maintenance person-
nel indicated their distrust to implement a vibration
monitoring system, but in the virtual meetings they
did not indicate their distrust, so the face-to-face
visits and interviews were fundamental to empathize.
• When maintenance or IT department heads did not
attend meetings, departmental staff presented less
feedback or suggestions. As a partial solution, the
GIDTEC team sent the meeting recording and de-
cision making consultations via email as a partial
solution.
Change of requirements: In the first four
phases, the maintenance department requested that
the monitoring system be wired and output to the
SCADA system, preferably using equipment of the
same brand as their PLCs that they had in operation.
After the test phase this request changed, they with-
drew these requirements and requested temperature
monitoring.
4.2 Observations on behalf of the industry
• Regarding the development of the project, they felt
part of and committed to the implementation; usu-
ally when they have implemented other projects the
vendor delivers a turnkey system, and it is little pos-
sible to make changes. In addition, the maintenance
personnel have validated the condition monitoring
system in their decision making process, so the system
measurements have been integrated into their com-
puterized maintenance management system.
 René Vinicio Sánchez et al. / IFAC PapersOnLine 55-19 (2022) 187–192 191
• The testing and especially the prototyping phases
they believe helped them change their paradigm re-
garding wireless communications and the need for
communication with the SCADA system.
• That the activities developed by GIDTEC were fun-
damental because they would not have been able to
do each of the phases of the project in an exhaustive
manner due to their day-to-day activities.
• They believe that the GIDTEC should have been
more familiar with the industry’s internal processes,
as this would have avoided delays due to communica-
tion and authorization issues.
• At the end of the project, the industry, together with
the university, made a video showing the industry’s
satisfaction, which can be viewed at: Link 2.
5. CONCLUSIONS
We present a case study of collaboration between the uni-
versity represented by GIDTEC, the paper industry and
the co-founder CEDIA. The project addressed the need
for a system that allows early detection of press bearing
failures and satisfies the requirements of the maintenance
and IT departments.
The time for the implementation of the project was six
months, for this reason, we considered it appropriate to
combine agile methodologies with design thinking. This
allowed us to monitor the progress of the project and
empathize with the needs of the industry.
The implementation of the press bearing condition moni-
toring system was developed in six phases, the test and
prototyping phases were the most influential to verify
compliance with the requirements and definition of the
system features.
The communication factors and the presence of the depart-
ment heads in the meetings were vital for the development
of the project.
6. ACKNOWLEDGMENT
We thank CEDIA and the Ecuadorian paper industry
for funding the project, and the Universidad Politécnica
Salesiana for supporting GIDTEC.
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