J. Inst. Eng. India Ser.
C (April 2023) 104(2):449–453
https://doi.org/10.1007/s40032-022-00900-1
ARTICLE OF PROFESSIONAL INTEREST
Creating Value for Reliability Centered Maintenance (RCM)
in Ship Machinery Maintenance from BIG Data and Artificial
Intelligence
Ulhas S. Kalghatgi1
Received: 24 May 2022 / Accepted: 4 October 2022 / Published online: 28 October 2022
© The Institution of Engineers (India) 2022
Abstract Seagoing ships transport nearly 90% (Interna-
tional Maritime Organization, in IMO’s contribution to sus-
tainable maritime development, 2012) of the world trade by
volume worldwide through a large network of maritime logis-
tics companies located in different time zones making it the
lifeline of the global economy. This makes it challenging for
the shipping companies to run their operations economically
ensuring the safety of life at sea and a pollution-free envi-
ronment. The introduction of Electronic Chart Display and
Information System onboard ships to improve safe naviga-
tion and the use of sensors to monitor machinery parameters
and track real-time ship performance have paved the way for
digital transformation in the maritime industry. These per-
formance monitoring tools though fundamental to improv-
ing fleet performance, fetch enormous data, however, their
complexity makes it challenging to deal with the 4 Vs, vol-
ume, velocity, veracity, and a variety associated with big data
terminology. This paper describes how ships can benefit by
deploying Big Data analytics, the Internet of Things and Arti-
ficial intelligence (AI) in enhancing the value of Reliability
Centered Maintenance (RCM) in ship maintenance and thus
are indispensable for the RCM. The author believes that the
synergy that will be created by using Big data, RCM and AI
concepts will enable the creation of a maintenance business
model that will eventually develop a new growth engine for
the stakeholders in the shipping industry.
Keywords Big data · RCM · Artificial intelligence ·
ECDIS · Internet of Things (IoT)
* Ulhas S. Kalghatgi
ulhassk@gmail.com
1
Navi Mumbai, Maharashtra 400703, India
Introduction
The maritime industry should be agile to adapt to emerg-
ing newer technology, using Big data analytics tools. With
an increasing degree of automation in bridge and machinery
control systems, a significant amount of data is generated,
making it well-nigh impossible to manually sieve the data,
analyze it and then use it to make quick decisions, whether
it is about ship’s performance, maintenance, make course
corrections en route, or even to supplement the spare parts
stock. Big data analytics tools are enablers to ship owners to
analyze and comprehend such capacious data that facilitates
decision-making.
Big Data is likely to be used in the following six principal
areas:
• Technical operation and maintenance,
• Ship’s energy efficiency,
• To improve the safety culture and score of the organiza-
tion,
• Managing and monitoring shipping traffic to reduce acci-
dents and environmental risks,
• Commercial operations to figure out the most valuable
customers and help businesses create new experiences,
services, and products,
• Autonomous ship operations.
A framework for Intelligent Reliability Centered
Maintenance Analysis
RCM, since its development in the late seventies, has been
historically relying heavily on manual processes to manage
the data, compiled by the shop floor operators/maintenance
staff ashore or by the ship’s crew, for decision-making at both
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strategic and tactical levels, for its successful implementation,
whether on shore-based industries or onboard ships.
RCM can gain immensely by making use of advanced tech-
nology, which is gaining rapid traction with the introduction
of the Internet of Things (IoT), Big Data, Artificial intelli-
gence (AI), use of sensors, etc. Land-based industries have
become tectonic to usher in sea changes in their maintenance
plan of plant machinery. The net result is less downtime,
greater availability of machinery, and keeping the wheels of
the business running smoothly. Shipping industries can repli-
cate this model to improve their footfall.
In the olden days, manning on ships was adequate; ships’
staff were conducting maintenance in a timebound manner,
adhering to the schedule as recommended by makers or ship
owners’ maintenance plans. But a drastic reduction in man-
ning scale and faster turnaround of ships has resulted in the
reduced time available to conduct maintenance, with the avail-
able crew onboard, within the stipulated time.
The COVID 2019 Pandemic had a multiplier effect on the
shipping sector creating a myriad of problems, which ship-
owners must overcome, such as keeping statutory certificates
valid, keeping the ship ready for surveys to be conducted
by Classification Society, Port state and Flag state inspec-
tions, ISM and ISPS audits, timely crew repatriation, etc. The
answer to this unprecedented problem lies the need for ship-
owners to have a Data-Driven Policy as a first step and then
moving toward IoT solutions, which will enable the ships’
crew to operate and maintain the ship efficiently, whether
offshore or when the ship is berthed. It is predicted that Big
Data in combination with IoT and AI will enable condition-
based maintenance to play a significant role in enhancing the
application of RCM onboard ships.
Definitions
Big Data and Big Data as a Concept
The term Big Data is a blanket term for the data so sizable and
labyrinthine that conventional operating system was unable to
process them [2]. However, today, it is a hypothesis [3] that
goes beyond the issue of dealing with immense data. Big data
analytics is not just about accumulating data but also covers
the process of analysis to discover the hidden insights, trends,
and correlations, which have the potential to bring a competi-
tive advantage to any industry, including maritime.
The industry has proposed several definitions of big data,
namely the one advanced by Gartner [4], which says the
concept "Big Data" is strongly linked to three (3) aspects,
called the famous "3Vs" the Volume, Velocity and Variety.
IBM has added the fourth characteristic “V,” Veracity mak-
ing it 4Vs. Oracle [5] has put forward the fifth “V” calling it
Value to make it more inclusive. However, keeping brevity in
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J. Inst. Eng. India Ser. C (April 2023) 104(2):449–453
perspective, the author has included only four Vs as shown in
Fig. 1, defined as follows:
• Volume applies to the magnitude of data, which could be
in terabytes, petabytes and beyond.
• Velocity refers to how quickly data is generated, entailing
distinct processing techniques
• Veracity refers to data precision and reliability. Datasets
from various sources may use different range to measure
the same variable, raising the issue of maintaining data
quality throughout the data life process.
• Variety means structural diversity of the data consisting of
unstructured data such as text, images, video, and audio.
What is Artificial Intelligence (AI)?
The term artificial intelligence refers to a set of technolo-
gies that enable computers to simulate human intelligence.
Examples of AI include speech recognition, such as directing
virtual assistants like Alexa to perform tasks, image recogni-
tion for identification, and autonomous driving. AI systems
introduced on autonomous ships can operate independently
without human interaction, reducing the error rate below that
of manned ships. AI will gradually transform the traditional
operations of the maritime industry.
Within the ambit of AI is included.
• Machine learning, the use of algorithms to learn and exe-
cute tasks without human intervention,
• Deep learning, using neural networks to find complex pat-
terns in high-volume data,
• Cognitive computing, simulating the functioning of the
human brain to solve complex problems, and natural lan-
guage processing
Fig. 1  4 Vs of Big data
J. Inst. Eng. India Ser. C (April 2023) 104(2):449–453
• Helping computers to understand and interpret human
language.
How to Create Value for RCM from Big Data
and Artificial Intelligence
A typical ship generates a large volume of data, captured
by deploying sensors, e.g., engine room machinery param-
eters, information from ECDIS, weather reports, tempera-
tures recorded by reefer containers of the cargo inside the
containers, cargo temperatures inside the holds of a coal
carrier, monitoring of container lashings tautness, etc. The
use of sensors is a widespread practice in the industry, to
capture physical changes such as deformation, vibration or
temperature all under real-life conditions that cannot always
be described by numerical models.
Shipping industries are on the cusp of embracing digi-
tal transformation to gain operational advantage over their
competitors; however, they must focus on crew training and
spread digital literacy to achieve digital transformation.
Three digital technologies—cloud computing, cyber
security and big data analytics—are at the heart of the digital
transformation. Adding artificial intelligence and IoT to these
repertoires of technologies will bring in not only a paradigm
shift in the maintenance practices being followed onboard
ships but will also be considered as groundbreaking evolu-
tion. This will enable the acceleration of the adoption of AI-
assisted ship operations and optimization of vessel mainte-
nance approaches based on RCM principles.
Preventive maintenance is planned based on propulsion
and auxiliary machinery parameters, which are at best less
accurate. These data help ship engineers to monitor the
machinery’s health and condition. In such a scenario, ship’s
superintendents are not involved on a real-time basis.
With this method of monitoring parameters, it is exceed-
ingly difficult to predict failure accurately. The drawbacks of
this method are as follows:
1. Upper limit of each parameter is not indicated.
2. Pre-failure warning does not occur, which reduces the
possibility to take remedial action before failure.
3. Engine room and deck logbook records are maintained
manually every 4 h which may give rise to data inaccu-
racy.
4. Preventive maintenance task is performed, though not
needed to just fulfil the maintenance schedule making the
machinery susceptible to failure.
Big data analytics and AI will endeavor to overcome the
above drawbacks, thus adding value to RCM in its applica-
tion to shipboard machinery maintenance.
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Key Drivers for Gaining Digital Ascendancy
The maritime sector delivers goods effectively and effi-
ciently around the globe on time, relying on Information
and Communication Technologies (ICTs). In addition, the
vessel performance data, which includes fuel consumption,
port stay, cargo manifestation sheets and bill of lading,
machinery parameters, and other vital information are con-
tinuously exchanged between shore and ship on a real-time
basis through Information Communication and Technology
(ICT) platform.
The quintessential amalgamation of technologies, namely
Cloud Computing, Cyber Security, Internet of Things (IoT),
and Artificial Intelligence (AI), takes place through ICT.
Communication Architecture
The high-level communication architecture of a ship shown in
Fig. 2 is a combination of terrestrial and satellite components,
as well as possible High-level Platform (HAP) elements. The
ship is connected to the remote Shore Control Center with
multiple redundant systems to ensure uninterrupted data flow.
Figure 2 illustrates how the networking is done between
ships and shore establishment and between ships and ports
using communication architecture and ICT. The intent of
this paper is not to dwell on autonomous ships, but to apply
the conceptualization of an autonomous ship to facilitate the
RCM implementation on board ships.
The Internet of Things (IoT) will be one of the key driv-
ers, impacting the maritime sector to make shipping more
efficient with the help of connected sensors and unified plat-
forms allowing the real-time monitoring of machinery sys-
tems onboard the ship.
IoT-based solutions can monitor variables including loca-
tions, temperature, pressure, shock, and humidity in seago-
ing vessels and exchange data among vessels and shore-based
data centers for further analysis and provide information to
masters, chief engineers, to take necessary actions, whether
machinery maintenance or course correction of a ship or
sequencing of loading and discharging of cargo at a differ-
ent port of calls. Such information will facilitate achieving
various energy efficiency and emission control standards in
shipping.
Emerging Technologies: Cloud and Edge
Computing
Emerging technologies such as cloud and edge comput-
ing are playing an increasingly important role in maritime
logistics and will also bring about sea changes in the way
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Fig. 2  High-level communication architecture of an autonomous ship
maintenance is carried out, which is based on the Potential
Failure (P-F) interval of machinery and not based on a time
scale, thus optimizing the maintenance cost onboard ship
thereby increasing the availability of machinery.
Applying cloud-based solutions in conjunction with high-
speed data links via satellite will help to connect vessels at
sea with operational matters ashore and maintenance service
providers. Such an approach will allow stakeholders to access
and share data stored in the cloud and provide insights based
on comprehensive information.
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J. Inst. Eng. India Ser. C (April 2023) 104(2):449–453
A step ahead is Edge Computing; IoT or edge computing
involves the use of tiny sensors and computing devices at or
near the points where instant action is taken using the data
generated by the sensors.
The confluence of IoT, AI and 5G will play an important
role in the remote control of autonomous ships in the future.
5G will replace fiber optic cables to minimize the cost of data
transportation from sensors to the shore office.
J. Inst. Eng. India Ser. C (April 2023) 104(2):449–453
Constraints and Challenges
The installation of IoT and other remote sensing devises may
pose various challenges to shipping industry under large-scale
data sets, so-called Big Data challenges, which must be over-
come before harnessing the full potential benefits of big data.
These could be:
1. Ensuring Sensor data quality and reliability to provide
useful information, to make informed decisions about
course correction, stoppage of machinery, or any other
emergency, that a ship may have to address.
2. Limitation of bandwidth to minimize the Data quantity:
This will reduce the transmission cost using high sea sat-
ellite communication.
3. Avoid Sensor degradation by tracking and monitoring
the health conditions of the sensors to prevent abnormal
detection and inconsistency.
4. Standardization of Data: This is a key to improving data
flow and enhancing interoperability and synergy.
5. Building trust in data to ensure to data accuracy because
datasets from diverse sources may use different scales to
measure the same variable. This raises issues of maintain-
ing data quality throughout the data lifecycle.
6. Focusing on right pool of digital talent by imparting sea-
farers and ship managers sufficient digital knowledge to
become partners in bringing about digital transformation
in shipping industry.
7. Paying attention to Cybersecurity and Data Protection
from cyber-attack, viruses, and malware to prevent dis-
ruption in ship operations to ensure business continuity.
8. Data distillation is essential to deal with disparate sets of
machinery installed onboard ships having different oper-
ating parameters, different ship types such as oil tankers,
which are fitted with cryogenic pumps. Failure to monitor
may have a serious impact on the operations of a vessel.
Future Research
The maritime industry needs to radically change its age-
old practices of manual recording of all parameters and take
recourse to AI to transform the traditional operational processes.
Consequently, the amount of research on the application of big
data and AI has increased manifold since 2012 [6]. Following
this trend, data-centric innovative technologies and new busi-
ness models are getting developed [6]. This transformation is
reshaping the maritime industry, providing new opportunities
to improve productivity, energy efficiency and sustainability.
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Conclusion
“Big data” does not refer to a single technology, but to the grow-
ing array of techniques to manage and extract actionable infor-
mation from data. This paper has described a new emerging
model, which can be used to create value for RCM by using BIG
Data and AI, thus minimizing the cost of maintenance, avoiding
downtime, and ensuring the availability of essential machinery.
Digitalization can reach its full potential when data flows are
seamless. The confluence of IoT, AI, and 5G will be the biggest
revolution in the next 30 years, transforming life in every aspect.
Edge computing is also important because it is too expensive
to transport everything to the cloud, putting a heavy burden on
the bandwidth. AI at the edge can filter out the waste and send
only the valuable data to the cloud, keeping in mind the data
security.
AI becoming “mainstream technology” will integrate with
other emerging technologies such as the Internet of Things
(IoT), Augmented Reality (AR), 3D printing, and edge comput-
ing that will play a role in shipboard operations and maintenance
in the future.
Funding The author declares that no funds, grants, or other support were
received during the preparation of this manuscript.
Declarations
Conflict of interest The author has no relevant financial or non-financial
interests to disclose. The author declares that there is no conflict of interest
regarding the publication of this paper.
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Publisher’s Note Springer Nature remains neutral with regard to
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