13th IFAC Workshop on Intelligent Manufacturing Systems

13th
13th IFAC
IFAC
August Workshop
Workshop
12-14, on Intelligent
on Intelligent
2019. Oshawa, CanadaManufacturing Systems
Manufacturing Systems
13th IFAC
August
August
13th Workshop
12-14,
12-14,
IFAC 2019.
Workshop on
on Intelligent
2019. Oshawa,
Oshawa, Canada
Canada
Intelligent Manufacturing Systems
Available online
Manufacturing at www.sciencedirect.com
Systems
13th IFAC
August
August Workshop
12-14,
12-14, on Intelligent
2019. Oshawa,
2019. Oshawa, Canada
CanadaManufacturing Systems
August 12-14, 2019. Oshawa, Canada
ScienceDirect
IFAC PapersOnLine 52-10 (2019) 91–96
Maintenance 4.0 Technologies for Sustainable Manufacturing – an Overview
Maintenance 4.0 Technologies for Sustainable Manufacturing – an Overview
Maintenance
Maintenance 4.0 Technologies for Sustainable Manufacturing – an Overview
Maintenance 4.0 Technologies
4.0 Technologies for Sustainable
for Sustainable
Małgorzata Jasiulewicz Manufacturing
Arkadiusz Gola** –
- Kaczmarek*,Manufacturing an Overview
– an Overview
Małgorzata Jasiulewicz - Kaczmarek*,  Arkadiusz Gola**
Małgorzata
Małgorzata Jasiulewicz Jasiulewicz -- Kaczmarek*,
Kaczmarek*, Arkadiusz Gola**
Arkadiusz Gola**
* Poznan University of Technology, Małgorzata Jasiulewicz
Faculty of Management 
- Kaczmarek*, Arkadiusz
Engineering, Gola**
Strzelecka 11, 60-965 Poznań, Poland
* Poznan University of Technology, Faculty of Management  Engineering, Strzelecka 11, 60-965 Poznań, Poland
* Poznan Poland
Poznan University
University (Tel: +48 500-007-701;
of Technology,
Technology, Facultye-mail:e-mail: malgorzata.jasiulewicz-kaczmarek@put.poznan.pl)
of Management
Management Engineering, Strzelecka
Strzelecka 11, 11, 60-965
60-965 Poznań,
Poznań, PolandPoland
* Poland (Tel: of +48 500-007-701; Faculty of malgorzata.jasiulewicz-kaczmarek@put.poznan.pl)
Engineering,
** * Poznan
Lublin UniversityUniversity
Poland of of Technology,
(Tel:
Technology,+48 500-007-701;
Institute Faculty
of of Management
e-mail:
Technological Engineering, Strzelecka
malgorzata.jasiulewicz-kaczmarek@put.poznan.pl)
Systems of Information, 20-618 11,Lublin,
60-965ul. Poznań, Poland 36,
Nadbystrzycka
** Poland (Tel: +48 500-007-701; e-mail: malgorzata.jasiulewicz-kaczmarek@put.poznan.pl) Lublin, ul. Nadbystrzycka 36,
**
Lublin University Poland of (Tel:
Technology,+48 500-007-701;
PolandInstitute of
(Tel:of+48 e-mail:
Technological malgorzata.jasiulewicz-kaczmarek@put.poznan.pl)
81 538 45 35; Systems
e-mail: of Information, 20-618
**
**Lublin University of Technology, PolandInstitute
(Tel: +48 Technological
81 538 45 35; Systems
e-mail: of a.gola@pollub.pl).
Information, 20-618 Lublin, ul. Nadbystrzycka 36,
a.gola@pollub.pl).
**Lublin University of Technology, Institute of Technological Systems of Information, 20-618 Lublin, ul. Nadbystrzycka 36,
Lublin University of Technology, PolandInstitute
(Tel: of Technological
+48 81 538 45 Systems
35; e-mail: of a.gola@pollub.pl).
Information, 20-618 Lublin, ul. Nadbystrzycka 36,
Poland (Tel: +48 81 538 45 35; e-mail: a.gola@pollub.pl).
Poland (Tel: +48 81 538 45 35; e-mail: a.gola@pollub.pl).
Abstract: Manufacturing is experiencing relevant changes under the challenges imposed by the
Abstract:
sustainable Manufacturing
economic development is experiencing model. relevantUnder this changes
model,under the challenges
the significant progress imposed by the
in advanced
Abstract:
sustainable
Abstract: Manufacturing
economic
Manufacturing is
development experiencing
is experiencing model. relevant
Under
relevant changes
this model,
changes under
the the challenges
significant
under the Meanwhile, progress
challenges imposedimposed
in by
by the
advanced the
technologies is providing new opportunities to enhance competitiveness. the in
maintenance
technologiesManufacturing
Abstract:
sustainable
sustainable economic
is providing
economic
is experiencing
development
new
development model. relevant
opportunities
model. Under
to enhance
Under
changes
this
this model,under
competitiveness.
model, the
the Meanwhile,
the significant challenges
significant progress
progress
imposed
the in by the
advanced
maintenance
advanced
function
sustainable is transforming
economic its
development role in order to better support value creation, both contributing to the
technologies is providing
function is transforming
technologies is providing newrole
its
new in model.
opportunities
opportunitiesorder toUndertobetter
to enhance
enhance
this model,
support the creation,
competitiveness.
value
competitiveness.
significant
Meanwhile,
both
Meanwhile,
progress the in
the
advanced
maintenance
contributing
maintenanceto the
economic
technologies
function isdimension as
is providing its
transforming well as
newrole extending
opportunities
in order its care
tobetter
enhancefor the environmental
competitiveness. and social
Meanwhile, aspects. Maintenance
the maintenance
function
economic
4.0 can break
function
isdimension
transforming as well
the trade-offs
isdimension
transforming
itsof
its as
role
the
role
in
extending
older
in
order
order itsto
tocare
strategies better
tocare
better for support
support
by the
value
value
environmental
enabling
support companies
value
creation,
creation,
and
creation,
both
to social
maximize
contributing
bothaspects.
contributing
bothaspects. Maintenance
the useful
contributing
to
to the
lifethe
to theof
economic
economic
4.0 can dimension
break the as
as
trade-offswell
well as
as
of extending
extending
the older its
its care
strategies for
for
by the
the environmental
environmental
enabling companies and
and to social
social
maximizeaspects.the Maintenance
Maintenance
useful life of
their
economic
4.0 can production
dimension
break the equipment
as well of
trade-offs while
as the
extending avoiding
older strategies unplanned
its care for by the
enablingdowntime,
environmental
companies minimizing
and to social
maximize planned
aspects.the downtime,
Maintenance
useful life of
4.0
their can
increasing break
production the
process trade-offs
equipment
and people of the
while
safety, older strategies
avoiding
minimizing unplanned by enabling
energy companies
downtime,
and resources to maximize
minimizing
consumption the
planned
and useful life
downtime, of
4.0
their canproduction
break the trade-offs
equipment ofwhile
the older strategies
avoiding unplanned by enabling companies
downtime, to maximize
minimizing the saving
planned useful costs.
life
downtime, of
their
increasing
The production
paper process
presents equipment
and
the people
possibility while
safety,of avoiding
minimizing
incorporation unplanned energy
new downtime,
and resources
technologies minimizing
into consumption
the planning, planned
and downtime,
saving
implementation, costs.
their
increasing
The production
process
paper presents equipment
and people
the possibility while
safety, avoiding
minimizing
of incorporation unplanned energy downtime,
and resources
new technologies minimizing
intoconsumption planned
the planning,and downtime,
saving
implementation, costs.
increasing
monitoring process and
and analysis people safety,
of maintenance minimizing
processes energy
that and resources
support consumption
sustainable and
production saving
in moderncosts.
increasing
The paper
monitoring process
presents
and and
the
analysis people
possibility
of safety,of
maintenance minimizing
incorporationprocesses energy
new and resources
technologies
that support into consumption
the
sustainable planning, and
production saving
implementation,
in costs.
modern
The paper
manufacturing presents the
companies. possibility of incorporation new technologies into the planning, implementation,
The paper
monitoring
manufacturing presents the
andcompanies. possibility
analysis of of maintenanceof incorporation
maintenance processes processes that new technologies
that support into
support sustainable the planning,
sustainable production implementation,
production in in modern
modern
monitoring and analysis
monitoring andcompanies.
analysis of maintenance processes that support sustainable production in modern
© 2019, IFAC
manufacturing
manufacturing
Keywords: (International
companies.sustainable
sustainability, Federationmanufacturing,
of Automatic Control) Hosting
sustainable by Elseviermaintenance,
maintenance, Ltd. All rightsIndustry
reserved.4.0.
manufacturing
Keywords: sustainability,companies.sustainable manufacturing, sustainable maintenance, maintenance, Industry 4.0.
Keywords: sustainability, sustainable
Keywords: sustainability, sustainable manufacturing,
manufacturing, sustainable maintenance,
 sustainable maintenance, maintenance,
maintenance, IndustryIndustry 4.0. 4.0.
Keywords: sustainability, sustainable manufacturing,  sustainable
that maintenance,
predicts failure maintenance,
makes Industry 4.0.
diagnosis and triggers
1. INTRODUCTION  that predictsactions failure makes diagnosis and triggers
1. INTRODUCTION  maintenance
that predicts failure(Lee et al.,
makes 2014). Maintenance
diagnosis and 4.0 is a
triggers
maintenance actions (Leenextet al., 2014). Maintenance 4.0 is a
Many authors (e.g. 1.
1. Seliger et al., 2008; Dubey et al., 2017) that
INTRODUCTION
INTRODUCTION new
that
predicts
term defining
predicts
maintenance
failure
the
failure
actions (Lee
makes
makes
et al.,
diagnosis
generation
diagnosis
2014). in theand
and
triggers
approach
triggers toa
Many authors (e.g.
haveManyconsidered the
Seliger et al., 2008; Dubey et al., 2017) new
1. INTRODUCTION
relevant role that technology development
term defining
maintenance actions
of
the
(Leenext
production 2014). Maintenance
generation
et equipment.
al., in the approach
Maintenance
Maintenance
4.0
4.0
4.0
is
isto
isa
authors (e.g. Seliger et al., maintenance
new term actions
term defining
defining (Lee
the next et al.,
nextequipment.2014). Maintenance
generation Maintenance
in the
the approach4.0
approach is isa
to
haveManyconsidered
authors the relevant
(e.g. Seliger role
et that2008;
al., 2008; Dubey
technology
Dubey et
et al.,
development
al., 2017)
2017) maintenance
new
about
of production
predicting the
future generation
failures in assetsin and
4.0 to
ultimately
has towards sustainable manufacturing. Technology influences new term defining the next generation in the
haveMany
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considered
towards (e.g.
the
sustainable Seliger
relevant et al.,
role
manufacturing. that2008; Dubeydevelopment
technology
Technology etinfluences
al., 2017) about maintenance of
of production
predicting future equipment.
failures in assets andapproach
Maintenance 4.0
ultimately to
is
have
and
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dimension
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Technology allows
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Maintenance
preventive
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assets and measure 4.0 by
4.0
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predicting
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generations to meet IT technologies into of the planning, implementation,
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an manufacturing
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2018;
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et al.,analysis of maintenance
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2019; Gola, companies
maintenance
2019).
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maintenance al.,
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Recently,
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and maintenance last few decades
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regarding the contribution
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environment.
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2. MAINTENANCE
2. MAINTENANCE are described.
FOR SUSTAINABLE
described.
FOR SUSTAINABLE
bring
economic for sustainable
perspective ofmanufacturing.
sustainability, Referring
transparency to the
and maintenance function are described.
MANUFACTURING
interconnection
economic perspectiveof processes allow
quality,their
of sustainability, optimization,
transparency and 2.
increasing
economic
interconnection
increasing
efficiency,
perspective
efficiency,of flexibility,
of sustainability,
processes
flexibility, allow
quality,
and customization
transparency
their
and optimization,
customization and 2. MAINTENANCE
MAINTENANCE MANUFACTURING FOR
FOR SUSTAINABLE
SUSTAINABLE
interconnection
(Peukert et al., of
2015). processes
Regarding allow
the their
ecological optimization,
dimension of During 2. MAINTENANCE
the last MANUFACTURING
five FORmaintenance
decades, SUSTAINABLE has radically
interconnection
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(Peukert et efficiency,
al., of
2015). processes
flexibility,
Regarding allow
quality,
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and
ecological optimization,
customization
dimension of MANUFACTURING
increasing
sustainability, efficiency,
prediction flexibility,
of energy quality,
consumption,and customization
reduction of During
changed the
according last five
not decades,
MANUFACTURING
only to the maintenance
technology has radically
requirements
increasing
(Peukert et
sustainability, efficiency,
et al.,
al.,prediction flexibility,
2015). Regarding
Regarding
of energy quality,
theconsumption,and customization
ecological dimension
dimension
reduction of changed
of During the last
according last not
five only
decades,
to the maintenance
technology has radically
requirements
(Peukert
waste and 2015).
resource consumption the ecological
are the key potential but During the
alsoaccording
because five decades,
ofonlytheto new maintenance has
market requirements. radically
(Peukertand
waste et al.,
sustainability, 2015). Regarding
prediction
resource of energy
consumption the ecological
consumption,
are the dimension
key reduction
potential of but
of During
changed also the
becauselast not
fiveof decades,
the the
new maintenance
technology
market has radically
requirements
requirements.
sustainability,
benefits (Dubey prediction
et al., 2017; of energy
Jabbour consumption,
et al.,the2018). reduction of changed
Maintenance according not
has evolved only to
from the technology
reactive function, requirements
becoming
sustainability,
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benefits and
(Dubey prediction
resource of energy
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et al., 2017; Jabbour consumption,
are
et key reduction
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2019 IFAC IMS
92 Małgorzata Jasiulewicz - Kaczmarek et al. / IFAC PapersOnLine 52-10 (2019) 91–96
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a green process. Currently it is considered as a process that
needed to be managed in a sustainable perspective.
Based on literature review and observation of industrial
practices, it was stated that maintenance contribution to business
competitive priorities and more sustainable manufacturing (SM)
operations has got two main dimensions, which are:
 the sustainability dimension,
 the life-cycle dimension.
The sustainability dimension is represented by the three
sustainability aspects: economic, environmental and social.
Maintenance contribution may be observed in all three
aspects (Fig. 1).
Figure 1. The contribution of maintenance processes in SM
Regarding the economic aspect of maintenance
contribution, there are four relevant economic factors
affected by the maintenance function: quality and
productivity, delivery on time, innovation and cost
(Jasiulewicz-Kaczmarek et al., 2018). With reference to the
environmental aspect the following factors may be
distinguished: prevention of environmental damage,
emissions reduction and land conservation, energy
consumption reduction and energy savings or efficiency
(Ajukumar & Gandhi, 2013; Franciosi et al., 2017). Finally, the
social aspect concerns the relationship of maintenance function
with its stakeholders within and outside the company, with a
particular focus on the maintenance personnel, who is affected
by decisions made in the maintenance department. Maintenance
contribution to social aspect is also linked to plant safety and
human safety, as a main means to avoid undesired failures and
minimize the consequences of the failures (Burduk &
Jagodziński, 2015; Pintelon & Muchiri, 2009; Ratnayake &
Antosz, 2017). The second dimension of maintenance
contribution to more SM system is life-cycle thinking (Fig. 2).
Sustainable Maintenance or Sustainability Centered
Maintenance (SCMn) has become a new challenge for
enterprises realizing concept of SM. Sari et al., (2015)
defined sustainable maintenance as ‘…all required processes
for ensuring the acceptable assets condition by eliminating
negative environmental impact, prudent in using resources,
concern for the safety of employees and stakeholders, while
at the same time economically sound’. Jasiulewicz-
Kaczmarek and Żywica (2018) defined SCMn as ‘a set of
proactive technical, economic and management activities
implemented throughout the whole life-cycle of a technical
facility aimed at realizing functions of a technical facility,
ensuring at the same time the achievement of goals and the
ability to create the economic, environmental and social
92
value for all stakeholders in the long-term horizon’.
Sustainable Maintenance should contribute to the
minimization of environmental and social impacts of a
system, the reduction of life cycle costs and enhancement of
equipment durability and socioeconomic well-being
(Afrinaldi et al., 2017).
Figure 2. Information flow in technical object life cycle
The objectives of the Sustainable Maintenance in a company
are: (1) to be in line with the business and profit objectives
(strategic decision rules and longer equipment life cycle); (2) to
keep the functional level of a machine and to preserve all its
characteristics above the level required from the viewpoint of the
environmental impact; (3) to be in line with social expectations
(satisfaction of employees, including their health and safety).
The essential question is ‘how to achieve specified goals
and what to do’. According Bilge et al., (2017) the enabling
technologies of the Maintenance 4.0, can contribute to
provide information necessary for sustainable maintenance
assessment, and they could become key-drivers in pursuit of
sustainable maintenance and asset life-cycle management.
3. MAINTENANCE 4.0 TECHNOLOGIES
It is not possible to look for solutions to the sustainable
maintenance issue without considering technology as an
integral component of the development. From the point of
view of maintenance, the development of new technologies
and end-user requirements have significantly affected both
the subject of maintenance operations (machines and
equipment) and the way of planning and implementing
maintenance activities. With regard to the application of new
technologies in machines and devices we use today, the most
common term 'smart machine'. The term “smart machine”
implies a machine that is better connected, more flexible,
more efficient and safe. It can quickly respond to new
demands. Smart Machine has three main components:
physical components, smart components and connectivity
components. Smart components are directly connected with
services related to the physical parts, while connectivity
allows exchanging information between the machine and its
environment, and enables services to exist outside the
physical machine itself. According Porter and Heppelmann
(2014) intelligence and connectivity enable an entirely new
set of machine functions and capabilities:
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 monitoring: machines enable the monitoring of a self-
condition, operation and external environment through
sensors and external data sources, and can alert users or
others stakeholders to changes in circumstances or
performance;
 control: machines can be controlled through remote
commands or algorithms that are built into the device or
reside in the machine cloud;
 optimization: smart, connected machines can apply
algorithms and analytics to in use or historical data to
improve output, utilization, and efficiency; and
 autonomy: monitoring, control and optimization
capabilities combine to allow smart, connected machines
to achieve a previously unattainable level of autonomy.
At the simplest level an autonomous machine does
operation using sensors and software on real time. More-
sophisticated machines are able to learn about their
environment, self-diagnose their own service needs, and
adapt to users’ preferences. Autonomy not only can
reduce the need for operators, but it can improve safety in
dangerous environments and facilitate operation in remote
locations.
This 'intelligent object of maintenance' enables the
incorporation of new technologies into the planning,
implementation, monitoring and analysis of maintenance
processes, such as: (1) smart sensors and smart devices (Zong
et al., 2017; Singh et al., 2014; Roy et al., 2016); (2) e-
CMMS (Iung et al., 2014; Lopes et al., 2016; Rødseth et al.,
2017); (3) diagnosis tools (Crespo Márquez & Iung, 2008);
(4) Prognosis tools (Lee et al., 2006; Crespo Márquez and
Iung, 2008; Muller et al., 2008); (5) Cloud -based tools
(Dillon et al., 2010; Zhong, et al., 2017); (6) simulation tools
(Alrabghi & Tiwari, 2015; Antosz & Ratnayake 2019); (7)
AR tools (Suarez-Warden et al., 2015; Klimant et al., 2017;
Kollatsch et al., 2017; del Amo et al., 2018). These
technologies defining the next generation in the approach to
maintenance of production equipment referred to in the
literature as Maintenance 4.0. Maintenance 4.0 is about
predicting future failures in assets and ultimately prescribing
the most effective preventive measure by applying advanced
analytic techniques on big data about technical condition,
usage, environment, maintenance history, and similar equip-
ment elsewhere and in fact anything that may correlate with
the performance of an asset.
A modern maintenance operation involves numerous de-
cision-making activities, requiring a large amount of infor-
mation and intensive computation. With the growing popu-
larity of condition monitoring, prognostics and cloud compu-
ting, the volume of data available for maintenance decision
making has increased significantly (Bokrantz et al., 2017;
Valis et al., 2018). The rise of big data and its usage can be
beneficial for operations and maintenance in order to be
proactive with regard to ongoing equipment maintenance and
upkeep. The use of data can provide more opportunity to
predict upcoming issues in a system or equipment and,
therefore utilize maintenance in a predictive manner, rather
than relying on the costly extremes – such as random
Preventative Maintenance or crisis-related Reactive
Maintenance. All of this Big Data is meaningless without
analysis. Analysis is what powers predictive maintenance and
93
separates it from more traditional, reactionary approaches to
equipment repair and replacement. Big data analytics is the
process of collecting, organizing and analyzing large sets of
data called big data to discover patterns and other useful
information. Big data analytics can help maintenance
organizations to better understand the information contained
within the data and will also help identify the data that is
most important to future decisions. Karim et al., (2016)
proposed concept for Maintenance Analytics (MA) that is
based on four interconnected time-lined phases (Fig. 3): (1)
“Maintenance Descriptive Analytics” focuses to discover and
describe what happened in the past; it summarizes collected
data from various maintenance sources and provides
summary statistics in terms of measures (e.g. number of
faults) and visualizations (e.g. failure rate chart); (2)
“Maintenance Diagnostic Analytics” focuses to understand
why something happened; it can basically be divided into
fault detection (i.e. indicating faults and malfunctions), fault
isolation (i.e. determining the cause and the related
component) and fault identification (i.e. designating the type
and the nature of the fault) (Kothamasu et al., 2006; Vogl et
al., 2016); (3) “Maintenance Predictive Analytics” focuses to
estimate what will happen in the future; it take current
machine conditions and past operation profiles into account
and either predict the probability that a machine operates
without a failure up to a time in the future (i.e. system health
state estimation) or calculate the remaining useful life (RUL)
as the time left before a failure occurs (Peng et al., 2010;
Elattar et al., 2016); (4) “Maintenance Prescriptive
analytics” which addresses what need to be done next; it
builds on the results of the previously described types,
integrates additional data (e.g. costs and re-source
information), and transforms them into actionable
maintenance recommendations to identify the optimal actions
and/or the optimal time of actions (Bousdekis et al., 2015).
Act
Value & Complexity
Analyze
Inform
Maintenance
Maintenance Prescriptive Analytics
Maintenance Predictive Analytics
Maintenance
Descriptive Analytics
Diagnostic Analytics
What happened? Why did it happend? What will happen? What shall we do?
Objectives Objectives Objectives Objectives
Optimal Time
Fault Detection
Measures System Health State of Maintenance
Fault Isolation
Visualizations
Fault Identification
Remaining Useful Life Optimal Action
of Maintenance
Figure 3. Maintenance Analytics time-lined phases
The aim of this concept is to facilitate maintenance actions
through enhanced understanding of data and information.
While descriptive and diagnostic MA are rather focused on the
past, predictive or prognostic MA is concerned with a more
forward-looking perspective to answer the question “What is
likely to happen?”. The application of big data analytics in
maintenance represents the fourth level of maturity in
predictive maintenance (Fig. 4).
Focusing on industrial scenarios, in the Maintenance 4.0
approaches, the smart sensors are considered as the real
enablers for industrial digitalization, since these sensors
become the unique data sources for all the services and big
data applications (Sikora et al., 2019; Zarnik et al., 2018).
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Big Data & Statistics
Level 1
Visual instection
periodic physical inspections;
conclusions are based solely of inspector’s expertise and
on inspector’s expertise
Content - periodic inspection (physical)
(the types of data they - checlist
use) - paper recording
Processes
(how that data is
- paper based condition data
- multiple inspection points
collected)
IT
(which hardware and - MS Excel / MS Access
software tools are used)
Figure 4. PdM maturity matrix (based on Mulders & Haarman, 2017)
These sensors translate physical actions from machines into
digital signals that communicate variables such as
temperature, vibration, or conductivity. Simply gathering data
on machinery from sensors is not enough. Maintenance 4.0
requires an Internet of Things infrastructure that wirelessly
connects assets to maintenance data center and enables the
collection and distribution of sensor data. The IoT is a new
revolution resulting from the convergence of maintenance
systems with advanced computing, sensors, and ubiquitous
communication systems. It is a transformative event where
countless industrial devices, both old and new, are beginning
to use Internet Protocol (IP) communication technologies.
There are several ways the IoT can improve the way
machinery and equipment are managed: (1) Greater adoption
of Predictive Maintenance. The main reason for applying IoT
to manage assets is predictive maintenance. Rather than
performing routine calendar-based inspections and
component replacement, predictive techniques monitor
equipment for pending failures and notify maintenance staff
when a part replacement is required. Sensors embedded in
equipment check for abnormal conditions and trigger work
orders when safe operating limits are breeched; (2) Real-Time
data analysis. The IoT takes Machine-to-Machine
(technologies that allow machines to communicate with each
other) to the next level by including a third element: data.
The availability of all machine data in one virtual network
gives original equipment manufacturers the ability to
aggregate and analyze the data to generate better predictive
analytic models; (3) Accurate performance metrics.
Availability, reliability and other key performance metrics
such as mean time between failures (MTBF) and mean time
to repair (MTTR) can be calculated automatically by the
system and fed to reporting dashboards. This removes the
human element in capturing all downtime, ensuring the data
is as accurate as possible; (4) Remote assets. The connected
assets generating their own work orders in the CMMS with a
proposed list of action items and recommended list of spares
to complete the job will reduce the mean time to repair; (5)
Recommended repair actions. The complete data on failure
Level 2
Instrument inspection
periodic inspections;
conclusions are based on
a combination
instrument read-outs
- periodic inspection (physical)
- instruments
- digital recording
- digital condition data
- single inspection points
- embedded instrument software
Level 4
Maintenance 4.0
Level 3
Real-time condition
monitoring
continuous real-time
continuous real-time monitoring of assets,
monitoring of assets, with alerts sent based on
with alerts given based on predictive techniques,
pre-established rules such as regression analysis
or critical levels.
Realiability
- continouos inspection (remote) - continouos inspection (remote)
- sensor - sensor and other data
- digital recording - digital recording
- digital condition data
- digital condition data - multiple inspection points
- multiple inspection points - digital environmet data
- digital maintenance history
- condition monitoring software
- condition monitoring software - big data platform
- condition database - wifi network
- statistical software
94
can be collected, segregated and performer in the real time
using cloud technology. Repair options can be taken
automatically by the system, and actions can be
recommended to the technician. All possible failure data will
be used to direct the repair, including system operating
conditions at the time of failure, previous repair data from the
CMMS, wear patterns and operating data from the
equipment. In effect, the technicians will be able to perform
their work more efficiently.
The next advanced technology which supports Maintenance
4.0 practices is Augmented Reality (AR) and Virtual Reality
(VR). Original ideas were developed in 1960s and since then a
steady progress has been made with the advancement of
computing power and image analysis. The main idea of VR is to
create a digital world in which the user can be immersed and
interact. In AR, the user can see the real world as well as digital
objects superimposed over it. Work instructions for maintenance
and assembly operations can be given directly to workers
through AR technologies. These technologies show promise for
assisting workers through integration of information into the
working environment, reducing the cognitive load on workers
and enabling better performance of various operations within
maintenance. AR has the potential to become a major tool for
the maintenance, by overlaying and integrating virtual
information on physical objects. Schwald and de Laval (2003)
presented an early study on the effectiveness of AR technologies
for maintenance training within industrial context. To justify
incorporation of AR technology to support aerospace
maintenance, Suarez-Warden et al. (2015 ) have presented an
analysis of the benefits of AR for aerospace maintenance
assembly task. The analysis incorporates the impact of
downtime and the maintenance variable cost reduction. Ong and
Zhu (2013) developed an AR-assisted real-time equipment
maintenance system. According authors by creating and
augmenting context-aware overlay of textual and graphical
maintenance instructions on the maintenance scene, remote
maintenance between equipment experts and maintenance
personnel can be achieved, thus improving maintenance
workflow and enhancing equipment. Del Amo et al., (2018)
believe that Augmented Reality (AR) is one of the most
interesting technologies in which enterprises should invest,
especially to improve service. And for this new project
implementation in the context of the ability to absorb and use
new technology in Maintenance 4.0. the most-important
competences are personal competencies (Patalas-Maliszewska
and Kłos, 2018)
5. CONCLUSIONS
Maintenance 4.0 can break the trade-offs of the older
strategies by enabling companies to maximize the useful life
of their production equipment while avoiding unplanned
downtime, minimizing planned downtime, increasing process
and people safety, minimizing energy and resources
consumption and saving costs. From a sustainable production
perspective, the Maintenance 4.0 contribution can be applied
to the following areas:
 Life cycle thinking. Technological advances, such as the
IoT, resulted in developments that influence life cycle
thinking. The IoT could underpin the Product System Service
design by using information feedback at any stage of the
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Product-Service life cycle. The availability of all machine
data in one virtual network gives original equipment
manufacturers the ability to aggregate and analyze the data to
generate better predictive analytic models. Moreover, IoT
provides information for continuous improvement, closer
relationship with stakeholders, resource efficiency and the
ability to meet sustainability.
 Services and aftersales. A key element of the strategy of
most companies involved in the production of machines is to
build solid, lasting relationships with its customers, providing
them with an independent, expert support and after sales
service. One of the elements of such support is remote
maintenance. According Rødseth et al., (2017) predictive
maintenance combined with remote maintenance will
typically reduce the maintenance cost from 10% to 40%.
 Resource/process. Maintenance prognostics techniques
could be used not only for calculating a RUL as
conventionally defined but for evaluating the energy
consumption, the energy efficiency, failures causing high
CO2-emissions or other environmental impact (Iung &
Levrat, 2014; Rødseth & Schjølberg, 2016). Conducting real-
time preventive maintenance of measurement sensors helps
improve the economic performance of manufacturing
processes and provides process stability.
 Inventories. Connected technologies can help
maintenance managers address the core challenge: the right
part in the right place, at the right time.
 Asset utilization. Predictive maintenance can drive
value by decreasing the planned machine downtime,
unplanned machine downtime, or changeover times. The
predictive maintenance typically decreases the total machine
downtime from 30% to 50% and extends the operation life
from 20% to 40% (Rødseth et al., 2017).
 Labor. Maintenance is a critical activity that takes place
at the manufacturing shop-floor. A proper level of detailed
maintenance instructions should be provided to the
maintenance personnel, according to their level of expertise.
With the aid of AR, various virtual information (e.g. virtual
components, disassembly instructions, diagnostic information,
etc.) that is needed to assist maintenance operators can be
overlaid directly onto the real workspace. Maintenance
workers can easily get the instructions in real time and remote
experts can collaborate with them intuitively. AR-assisted
disassembly guidance could significantly reduce the workload
of maintenance workers (Ong & Zhu, 2013).
Nevertheless, despite the fact that many authors point to the
wide range of applications of new maintenance technologies
for the implementation of economic, environmental and
social challenges of sustainable production, it can only be
said today, according to Franciosi et al., (2018) that ‘the role
of Maintenance 4.0 for sustainable manufacturing is still in
its infancy and it has big potentiality that need to be
investigated’.
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