3rd International Conference on Internet of Things and Connected Technologies (ICIoTCT), 2018

Development of Decision Support System (DSS) Framework for Predictive

Maintenance of Rolling Element Bearing in the Emerging Era of Industry 4.0

Hardik Majiwalaa, Pankaj Gandhib, Parag Sanghanic

a
Assistant Professor, School of Engineering, P. P. Savani University, Gujarat 394125, India
b
Associate Professor, School of Engineering, P. P. Savani University, Gujarat 394125, India
c
Executive Dean, School of Management, P. P. Savani University, Gujarat 394125, India

Abstract: The aim of this paper is to framework the architecture of decision support system (DSS) based on data generated by vibration analyzer for
predictive maintenance of rolling element bearing in the emerging era of industry 4.0. Inspired by big data generated in manufacturing plant and necessity
of predictive maintenance decision making cell, the framework developed for managers to trigger the decision related to breakdown of machines. This
study work has been carried out at one of biggest fabrication facilities in Gujarat which is going towards industry 4.0 paradigm. The case of one of
predictive maintenance technique; Vibration analysis has been done for the bearing and the failure prediction of rolling element bearing. For the same
case, architecture model of maintenance activities; Majiwala-Gandhi Maintenance Charter Model (MGMC) has been developed to help the managers to
make the decision. Same decision support system can be applied to other machine maintenance in manufacturing industries. Results and findings from the
study show that current solution algorithms; Majiwala-Gandhi Maintenance Charter Model can be useful to large data sets to lay out executable decisions
for managers.

Keywords: Predictive maintenance, Rolling element bearing, Vibration analysis, Decision Support system, Industry 4.0
Nomenclature
n Shaft speed
Nb Number of rolling element
FTF Fundamental train frequency of the cage or retainer
BSF Ball spin frequency
BPFO Ball pass frequency of outer race way
BPFI Ball pass frequency of inner race way
1. Introduction
A decision support system (DSS) is an information system
application that supports decision making. DSS tend to be used in
analyzing alternatives, trial and error search for solutions, and Planning.
In manufacturing industry, taking decision in day to day life for
maintenance system is very important. Decision varies from different
structure that can be provided for taking them. A structured decision can
be pre-specified or preplanned, whereas an unstructured decision cannot.
A structured decision has unmistakable decision rules can be specified in
advance as so called programmable decision. The same term does not
necessarily mean that the decision taken is automated. An unstructured
decision has no explicit decision rules to take in advance and also called
as non-programmable decision. Such structured decision tends to be
frequently repeated and routine; unstructured decision tends to be less
frequently repeated and no routine. Machine failures due to poor
maintenance and ignorance of observations are kinds of unstructured
problems in industry (Davis and Olson, 2016). Present work has been
carried out at one of largest fabrication facility in Surat, Gujarat. In
manufacturing industries, maintenance decision making can be described
as consisting three major phase: (i) Search out opportunities or problems,
(ii) Design to analyze opportunity to generate solutions, and (iii) Choice
to select alternatives and implement the chosen one. This maintenance
decision may be based on outcomes that are known with risk, certainty,
uncertain probability. Maintenance decision making in industries
frequently occurs in stress situation where all outcomes appear critical.
Under same conditions personnel use various coping methods which may
yield unsatisfactory results. For the same it is required to develop decision
support system to predict failure in industries. Rolling-element bearing is
commonly used and most important part in any heavy machineries,
petrochemical, paper, power plant, and manufacturing industries. If rolling
element bearing running smooth, it said to be quiet and proper working of
all elements of bearing. In manufacturing application if any flaw arise in
bearing element, it may cause downtime of machines leads to production
losses, machine downtime, and economic losses. Thus, it is very essential
to predict the presence of flaws in rolling element precisely. It is required
to develop decision support system for predictive maintenance of bearing
in critical machines in plant. The prediction of defective or deteriorated
element in bearing can be prophesied by predictive maintenance technique
i.e. Vibration analysis (Mobley, 1990). Vibration monitoring and trending
of any machines gives the estimation of running period time of machine
element bearing and deterioration of any part in rolling bearing.
2. Literature Review
Literature review comprised here in two sections; Decision support
system for maintenance activity in manufacturing industries, vibration
analysis case study in different types of industries. Present work relate to

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integration of decision making system and maintenance techniques. The
theoretical framework and architectural design (Bumblauskas et al., 2017)
for smart decision support system for maintenance has been prepared
based on 500 Fortune Company. SMDSS has been applied in services and
manufacturing based company and this optimized algorithms applied to
large set of unstructured decision for maintenance managers. The
integration of different maintenance techniques and decision making
systems (Reina et al., 2016) has been made to minimize the cost life cycle
for manufacturing system. An industrial case study (Mabkhot, Al-Samhan
and Darmoul, 2016) has been illustrated on reconfiguration of
manufacturing system to support the different information system and
models to take advantage of flexibility of manufacturing system.
Maintenance decision making support (Lin, Luo and Zhong, 2017) has
been developed and applied to aircraft fleet. Real time equipment
condition and information collection, condition-based maintenance, and
reliability assessment has been simplified by decision based maintenance
support system. Saving of energy and sustainable improvements using
smart decision making system in plant (Simeone et al., 2016) has been
demonstrated in reduction of heat recovery unit payback period in
manufacturing industries. The application of quality control tools
(Yazdani et al., 2017) has been proposed in development of decision
making model in supply chain and logistics to enable sustainable decision
making process and continuous successful outcomes.
The second part of literature includes vibration case study used in
manufacturing units and requirement of smart decision making system.
An analytical method (Tandon and Choudhury, 1997) for the
extrapolation of vibration signs of rolling element bearing and amounts of
important frequency signals. Different defect occurrence has been
considered on rolling-element bearing under axial and radial loads. The
vibration signals (Senthilkumar, Vikram and Pradeep, 2015) formed in
lath machine has been studied during real operating condition comprising
rolling element bearing, gears, and belt drives. Spherical roller bearing
defect occurrences have been premeditated and compared it with real
measured data. From that faulty cage has been found. The frequencies
reactions of deep groove ball bearing (Raghavendra and
Karabasanagouda, 2014) have been analyzed and statistical parameter
have been investigated for defective bearing elements. Vibration
monitoring (Orhan, Akturk and Celik, 2006) has been carried out and
studied for various case study to calculate failure and also inspected
machineries which was running at real operated condition by spectral
analysis. The location, defect size in bearing and effect of defect in
vibration signals (Patil et al., 2010) has been investigated for ball rolling
bearing vibration. Same author also offered analytical model for restricts
defect and its result on ball rolling bearing. Different size bearing defect
have been examined and likened it with upright bearing. The case study of
paper mill (Al-Najjar, 2000) has been carried out and estimate bearing
failure approach by observed bands and defect development pattern of
rolling element bearing. A case study on wire and tyre plants (Karabay
and Uzman, 2009) has been studied to know the prominence of untimely
detection of outages in different rotating machines elements using
vibration analysis. In this work, the use of vibration trending, monitoring
its analysis has been carried out on rotating element of machines at one of
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leading fabrication facility in surat, Gujarat. Data generated from
vibration measurement is unstructured data. It is too important task for
manager to trigger decision at right time at right place. If any outages of
machine in plant due to improper maintenance may leads to economical
loss and production losses. The aim of this study was finding of different
types of defect rise on rolling element bearing and develop sustainable
decision making support system for maintenance activity in
manufacturing plant. The architecture of maintenance charter decision
making support system model has been proposed for managers to trigger
the right decision at right time.Industry 4.0 is one of the emerging concept
in manufacturing domain to operate assembly/production line in full
automated mode. Such types of automated practices relies on data pool.
Based on industrial experience it has been found that every machines
generates plenty of data pertaining to its functioning. The big data
generated from the various activities in manufacturing domain (Lee, J.,
Kao, H, and Yang, S., 2014) can be used for the predictive maintenance
purpose. If such data are not properly analyzed and framed in suitable
structure than it can classified as a managing the big data. Cyber-Physical
Systems architecture has been developed for Industry 4.0-based
manufacturing systems (Lee, Bagheri and Kao., 2015). Research studies
have indicated that the manufacturing landscape of industry 4.0 is effected
by virtualization, decentralization and network topology (Brettel et al.,
2014). For efficient functioning of Industry 4.0, there is a need to have
proper data analysis and information generation for decision making. This
particular DSS framework will help to the organizations which are
following industry 4.0 concept.
This framework will help to maintenance manager and make him
enable to prepare blue print of various maintenance activities such as,
Breakdown maintenance, Scheduling of preventive maintenance,
condition based monitoring, machine parts replacement and vendor
selection for component supply.
3. Vibration Data Collection
SKF Micrology GX CMXA 70 Vibration analyzer is used to collect
and process the vibration data. Vibration analyzer performs condition
monitoring of rotating elements of machineries generally used in
manufacturing, power industries and petrochemical. Analyzer basically is
handy type that includes vibration data gathering, Verification and
processing over the range of 0.16 Hz to 40 KHz frequency. Parameter
which is to be set to take vibration data is shown in Table.1. Bearing
vibration assessment has been done by SKF make technology; (gE)
envelope acceleration (Application notes, SKF Reliability Systems 2003).
Such SKF vibration measuring analyzer comprise of sensor, power
electrical circuits which convert signs from time domain vibration to
frequency domain technology (FFT), memory is used for store the data
and ports to connect vibration analyzer to personal computer system to
transfer the captured data. Accelerometer, one type of sensor was used to
get a readings and sensitivity of vibration analyzer is 100 mV/g.
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 3rd International Conference on Internet of Things and Connected Technologies (ICIoTCT), 2018

Table 1 – Parameter to be set n d

Number of spectral lines 400
Window type Hanning
Spectral average mode Normal
Frequency range 0.18Hz to 40KHz
Detection RMS
Parameters has been set to take vibration measurement. Frequency
spectrum gives type of defect in the bearings and gE technology graph
gives severity defect in the bearings. Many Case studies have been carried
out in paper mill (Brown and Jorgensen, Application note) and Petro
chemical plant (Brown and Jorgensen Application note). Generally,
vibration readings were taken in three directions; Horizontal, Axial, and
Vertical. Vibration readings were taken in the vertical direction to
categorize the health of rotating elements of machines because signals
obtained from the vertical direction are most dominant as compare to
other two direction (Senthilkumar, Vikram and Pradeep, 2015).
4. Defect Frequency Analysis
Defective rolling element bearing generate different vibration
frequencies at different rotational speed that depends upon bearing
geometry shown in Fig. 1. These rotational frequencies are associated to
motion of rolling element, races and cage.
BPFI = Nb [1 + cos(α)] (4)
2 D
The mentioned above equations is used to calculate the defect
frequencies of specified different types of bearing. The running speed of
shaft is one of the criteria from where defect frequencies calculated under
the operational condition. Shaft speed may be vary and depend upon the
condition at which machine runs. Many times, Defect frequencies
calculate from equations may deviate due to same reason. When defect is
arises in the any elements of bearing i.e Cage, Inner race, Outer race, ball
spin, the sidebands, Defect frequencies and its order is become high. It
also may happen when any manufacturing defect is there and it is not
healthy for bearing condition (Randall and Antoni 2011). Defect
frequency is generally used to identify the defect in rolling element
bearing in any plant. The most critical thing in plant is the breakdown of
bearing in machineries and its leads to production losses and economical
losses. It is very important to predict breakdown in such critical machine.
The automatic decision making support system has to be develop so that
all steps and procedure to be follow to solve problem operates
automatically and it gives the managers liberty to make decision
effectively. Defect frequencies of bearing have calculated to do the study
of defective bearing elements. The Sample defect frequencies of bearing
used in this case study are given in Table 2.
Table 2 – Defect Frequencies for Bearing
Shaft
FTF BSF BPFO BPFI
Bearing type speed Nb
(CPM) (CPM) (CPM) (CPM)
(RPM)
Sample Bearing 900 22 394.8 56.29 8656.5 11114.4

Vibration reading of critical rotating elements of the plant is

Fig. 1 - Bearing Geometry
Any defect on bearing create predictable vibration frequencies and
different component flaw i.e. rolling element outer race, inner race, ball
and cage; generate particular defect frequency calculate from following
equation (1)-(4) mentioned by Senthilkumar, Vikram and Pradeep (2015).
recorded at regular basis. The vibration probe is attached to rotating
elements and it is recorded at desired direction i.e. Horizontal, Vertical
and axial. Different bearing has different defect frequencies. The sample
defect frequencies for SKF make 7020 CDGA bearing has been
calculated. Such defect frequencies said to be critical when it reach to
danger boundary reading of RMS value of velocity of vibration. Boundary
readings have been classified in green, yellow and red colors indicated
less danger respectively as shown in Table 3 (ISO Standard 10816-1:
Mechanical vibration).

n d
FTF = [1 − cos(α)] (1)
2 D

n d d 2
BSF = ( ) [1 − ( ) cos 2 (α)] (2)
2 D D

n d
BPFO = Nb [1 − cos(α)] (3)
2 D

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Table 2 – Evaluation Vibration Magnitude (Criteria Zone)

Velocity Velocity Range Limit and Machine Classes ISO Standard
Severity 10816-1
Large Machine
Small Medium
Mm/s Rigid Less Rigid
Machine Machine
RMS Support Support
(Class I) (Class II)
(Class III) (Class IV)
0.28
0.45 Good
Good
0.71 Good
Good
1.12
Satisfactory
1.80
Satisfactory
2.80
Alert Satisfactory
4.50
Alert Satisfactory
7.10
Alert
11.20
Alert
18.00 Alarm Fig. 2 - Sample spectrum graph
Alarm
28.00 Alarm
Alarm
45.00

GOOD – Those machines that are operating within the satisfactory limits
of Vibration values as per ISO-10816.

ALERT – Those machines that are operating above the satisfactory limits
of Vibration values as per ISO-10816. It is usually recommended to plan
the maintenance action at the earliest available opportunity; this would
help reducing the after effects of any failure as well as properly plan the
activity.

ALARM – Those machines that are operating in most abnormal condition

and it is usually recommended to immediately take maintenance action, so
as to avoid any catastrophic failure.

Priority:
1: ALARM 2: ALERT 3: GOOD

By analyzing the captured data, machines are classified as per its health
condition (i.e. normal, alert, and alarm) and give it priority to take
corrective action on it. The surveillance report is generated including its
velocity value, legend, observation and its corrective action. The vibration
reading of critical rotating parts recorded continuously and failure
prediction is taken as per RMS value reading of vibration which is taken
by envelope signal processing method of vibration monitoring. The
spectrum graph and gE graph is generated in SKF make vibration
analyzer. The sample reading graphs; spectrum graph and gE graph is
shown in figure.2 & 3.
Fig. 3 - Sample gE graph
It is very important to take this reading in consideration in plant
during the maintenance of critical machine. Maintenance manager is
responsible to make such type of decision. Developing such decision
making support system is much more important to make decision in day
to day life. The architecture of maintenance charter decision making
support system model has been proposed in next section to make decision
for maintenance of critical machines at efficient way.

5. Majiwala & Gandhi Maintenance Charter (MGMC)

Model

This study has been carried out at one of the largest huge
equipment fabrication facility. The objective of the project is to take
decision in an accurate and effective way regarding machine breakdown.
The maintenance manager has to depend upon breakdown data and data

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 3rd International Conference on Internet of Things and Connected Technologies (ICIoTCT), 2018

characterized different machines. Based on brainstorming session and

industrial experience, maintenance charter model (Majiwala and Gandhi
2017) developed by authors Majiwala and Gandhi. Hence forward the
same model is termed as Majiwala-Gandhi maintenance model for
rotating element. The process chart is shown in figure 4 to analyze and
make effective decision making support system. MGMC Model includes
subset of all activities includes; Breakdown entry, supervisor role, task to
be perform by workman, inventory system, and purchase of spare parts.
Data generated from vibration analyzer is used to predict the failure in the
rolling element bearing. Continuous monitoring of such critical parts
using predictive maintenance techniques is done and data is collected in
the system. As per ISO 10816-1 (ISO Standard 10816-1: Mechanical
vibration), the severity of problem is categorized, if it is in red zone, it is
required to take action on that particular critical machine immediately.
Such information regarding to take action on machines is sent to managers
with recommendation. MGMC Model will also give the data regarding
inventory and purchase. The module of inventory and purchase is
connected with maintenance module to check the availability of spare
used in machine assembly. The whole charter model is shown in figure.4
is used for vibration analysis and can be used for the predictive
maintenance technique; Thermography and wear debris analysis. MGMC
Model can help to manager to make decision on failure of critical
machines in manufacturing plant.

Fig. 4 - Majiwala-Gandhi Maintenance Charter (MGMC) Model

6. Conclusion

In this article, the predictive maintenance technique; Vibration

analysis has been done on rolling element bearing and predict the failure
in bearing elements. Generally, at the basis of data generated in vibration
analysis, the decision regarding maintenance of critical machines in the
plant is taken by the managers. The process flow of maintenance
department has been suggested to take decision regarding maintenance of
critical machine and inventory of parts in area of maintenance and
reliability across the internal supply chain. The technique and modeling
used to carry out predictive maintenance in plant is comparatively new

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 3rd International Conference on Internet of Things and Connected Technologies (ICIoTCT), 2018

paradigm. It is even more becoming important to differentiate between Karabay, S. and Uzman, I. (2009) Importance of early detection of
different maintenance strategies and model driven techniques. This Paper maintenance problems in rotating machines in management of plants: Case
offers a practice for establishing the predictive maintenance tactics, studies from wire and tyre plants, Engineering Failure Analysis, 16, 212–
considerations and recommendations for remote monitoring and help to 224
managers to make decision using Majiwala-Gandhi Maintenance Charter Lin, L., Luo, B., and Zhong, S.S. (2017). Development and application of
(MGMC) Model based decision support system. The activities like maintenance decision-making support system for aircraft fleet, Advances in
unplanned or planned maintenance, the severity of machine failure, Engineering Software, Volume 114, 192-207
emergency planning, and inventory of spare part can be categorized into Lee, J., Bagheri, B., and Kao, H. (2015) A Cyber-Physical Systems
architecture for Industry 4.0-based manufacturing systems, Manufacturing
subset of MGMC Model. MGMC Model can be further explored in the
Letters, 3, 18-23
Industry 4.0, Industrial CPS, artificial intelligence and Internet of Things
Lee, J., Kao, H., Yang, S. (2014) Service innovation and smart analytics for
(IOT) to offer decision making support maintenance recommendations.
Industry 4.0 and big data environment, Procedia CIRP , 16, 3-8
These types of human-Computer machines interaction is the era of much
Mabkhot, M.M., Al-Samhan, A.M. and Darmoul, S. (2016) An information
current research and rapid development in industry. If real operating time model to support reconfiguration of manufacturing systems, IFAC-Papers
monitoring shows to be precise, the area of service provider could save On Line, 49-5, 037–042
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