The document discusses various maintenance strategies, focusing on predictive maintenance (PdM), preventive maintenance (PM), and condition-based maintenance (CBM). It highlights examples from the automotive industry, specifically BMW and Volvo, illustrating how these strategies can improve customer satisfaction and service efficiency. The conclusion emphasizes the importance of sophisticated maintenance approaches in enhancing product reliability and customer service while reducing operational costs.

1. Predictive Maintenance Fredrik Ljungberg [email_address]

2. Agenda Maintenance from an overall perspective Examples Food for thoughts

3. Background Broken  Repair 1. To restore to sound condition after damage or injury; fix: repaired the broken watch. 2. To set right; remedy: repair an oversight. 3. To renew or revitalize. 4. To make up for or compensate for (a loss or wrong, for example). Maintenance 1. The act of maintaining or the state of being maintained. 2. The work of keeping something in proper condition; upkeep. 3. a. Provision of support or livelihood: took over the maintenance of her family. b. Means of support or livelihood: was ordered to pay maintenance for both children. 4. Law The unlawful meddling in a suit by providing either party with the means to carry it on.

4. OK  Broken  Repair Repair OK

5. OK  Maint  OK  Broken  Repair Good enough Broken OK Maint Repair Maint

6. Uptime circle ( Marko Vainio )

7. Maintenance concepts Maintenance Actions to keep a product in proper condition Preventive Maintenance (PM) Scheduled maintenance tasks to extend the time of proper condition Condition Based Maintenance (CBM) Maintenance actions based on the condition of the product Need for what service now? Predictive Maintenance (PdM) Need for maintenance actions predicted in advance Need for service when? Adaptive Maintenance (AD) Adapt content of service to the actual condition of the product

8. Examples from the car industry

9. BMW Condition Based Service Service concept for premium segment Service schedule d based on the status of the vehicle (its condition) Vehicle checks continuously the status of parts, fluid levels and mileage data and makes this information available to drivers The customer is prompted when service is needed Vehicle data saved in the key ” TeleService ” sends the data to the BMW service partner to plan service more effective Photo: BMW

10. Pilot project: Service Notification Objective To improve Customer Satisfaction To improve planning and scheduling of service in the workshop To reduce administration for service booking To provide service for customers more rapidly Photo: Volvo Cars

11. Pilot project: Service Notification Approx. 200 cars for 1 year Software added to phone module SMS every 1 000 km Conclusion Customers pleased with this way of booking services SMS from car to VCC back office Service need assessment by server software Customer gets email with web form Web form filled in and sent to workshop Workshop propose time for service Customer confirms Service of car

12. Examples from the industrial domain

13. CBM: Condition Based Maintenance Analysis of values reported by sensors will result in a decision if a maintenance should be done or not Pressure sensors Vibration sensors Temperature sensors Voltage and ampere meters Flow meters Can be mixed with other maintenance strategies, for instance RCM

14. PM: Preventive Maintenance Scheduled maintenance tasks, e.g., infrared temperature analysis Analogue measurement often used because more details Photo: Infrared Services

15. RCM : Reliability Centered Maintenance An approach to the management of reliability of complex products SAE JA1011 Usage Requirements on maintenance processes Evaluate maintenance processes Basics Analysis of consequences of failures Failures that lead to death, environmental issues or major economical losses should be designed out of the system Cost of maintenance tasks should be lower than cost of failure Photo: Vattenfall

16. RCM : Reliability Centered Maintenance Type1  death or environmental pollution Type2  downtime in production Type3  repair costs Type1: Should be designed out of the system or have PM tasks that make the probability of failure to near zero Type2 and 3: Tasks assigned to minimize the failure probability but only if cost of the task is less than the cost of a failure. Photo: ABB

17. RCM : Reliability Centered Maintenance NAVAIR The Naval Air Systems Command is a United States Navy command Partly used by SKF and Göteborg Energi Very complex  few companies apply the entire process/model Photo: NavAir

18. Development of maintenance Repair after failure Inspect, lubricate Unscheduled inspection and lubrication of components Preventive Maintenance Scheduled maintenance based upon probability of failure Systematic Planning and Scheduling Add feedback to improve maintenance, e.g., if a service seems applicable, if services missing, etc. Predictive Maintenance Maintenance based upon prediction of failure, e.g., time in operation

19. Development of maintenance Root cause analysis Investigation of causes to breakdown Reliability Centered Maintenance A sophisticated approach to maintenance Operator Maintenance The operator has been assigned tasks for maintenance and optimization Concurrent Engineering

20. Notes SKF From firefighting to maintenance Maintenance including improvements From an isolated task for a central unit to involve large parts of the company

21. Successful maintenance

22. Aspects of maintenance Worth doing? Follow-up Right tasks Right frequency Right techniques Motivation Detailed Structured

23. Add improvements Good enough Broken OK Maintenance Improved Optimized Improvements

24. Everybody needs to be involved What data to log? What values imply faults? (now or later) What methods will be required to find reason for fault? What methods and parts are required to repair fault? What methods are most successful? Parts logistics (and dev./update software) Workshop scheduling Customer interaction Off-board system Back office analysis Back office systems PD MA AM

25. Why sophisticated maintenance when parts sales is so important? For some companies in the industry: Selling vehicles: +/- 0 Sales of original spare parts: + May i mproved services imply less parts sales in the AM ? If so, w hy improve maintenance? Some possible reasons J D Powers and other surveys of customer satisfaction New business models require new models for the AM More loyal customers Enables new kinds of services

26. The formula ? Improved maint . + new offers /services > Today’s maint. + parts sales

27. Technical problems and customer-experienced problems Technical errors that the customer does not experience as problems Experienced problems but no technical error, e.g., configuration not proper (seat heater 0 degrees as default) Cust om er-experienced technical errors

28. Problems and services 1 Non-technical service 2 Software campaigns addressing customer-experienced problems, and soft offer 3 Software campaigns addressing problems of which the customer is not aware 4 Non-applicable services

29. Redefine the scope of maintenance ? Maintenance of the product Ensure ”technical problems” are managed as efficiently as possible Efficient maintenance of technical products What product data to log? What product values imply faults? (now or later) What methods will be required to find reason for fault in the product ? … Maintenance of the customer Ensure ”customer experienced problems” are managed as efficiently as possible Efficient maintenance and sales of new services What customer data to log? What customer values imply faults? (now or later) What methods will be required to find reason for fault in the customer ? …

30. Thank you!