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Industry 4.0 and Smart Maintenance represent a great opportunity to make manufacturing and maintenance more effective, safer, and reliable. However, they also represent massive change and corresponding challenges for industrial companies, as many different options and starting points have to be weighed and the individual right paths for achieving Smart Maintenance need to be identified. In our paper, we describe our approach to evaluating maintenance organizations in a case study for the oil and gas industry, developing a shared vision for the future, and deriving economical and effective measures. We will demonstrate our approach, by showcasing a specific example from the oil and gas industry, where a need for action on HSE-relevant critical flanges in the company's piping systems was identified. We describe the steps, that were taken to identify the need for action, the specifications of the project and the criticality analysis of the piping system. This resulted in the derivation of a digitalization measure for critical flanges, which was first commercially analyzed and then the flanges were equipped with a continuous monitoring solution. Finally, a conclusion is drawn on the performed procedure and the achieved improvements.
Electricity generated by wind turbines (WT) is a pillar of the transition to renewable energy [1]. In order to economically utilize WTs, operating and maintenance costs, which account for 25% of total electricity generation costs in onshore WTs, are a focus of cost reduction activities [2]. A prescriptive maintenance approach can support in achieving this goal. Prescriptive maintenance is a maintenance approach, where asset condition data is collected and analyzed to recommend specific actions to prevent breakdowns and reduce downtimes. However, the processing and analysis of data is quite complex. Especially unstructured data (such as comments of service technicians in free text fields) is often left unused, as companies, mostly SMEs lack the capacity to carry out these analyses. In this work we propose an approach to utilize the information from service reports, maintenance reports as well as status records from SCADA systems for the development of a prescriptive maintenance approach to onshore WTs. To achieve this, an ontology was utilized in this approach to codify implicit knowledge of service technicians and aid in making unstructured data usable for further analysis. The ontology was used to link historical service and maintenance reports with status codes, thus enabling automated analysis. In interviews with WT topic experts and through further research, damage mechanisms and corresponding maintenance measures were identified and a measure catalogue was developed to support service and maintenance activities. The recognition of the root cause of problems allows for a prescriptive maintenance approach that recommends targeted actions to reduce downtimes and optimize maintenance activities, it also allows to effectively control the outcome of maintenance activities and optimize their execution.
Die Digitalisierung und steigende Wettbewerbsintensität im Maschinen- und Anlagenbau zwingt Unternehmen dazu, ihre Wettbewerbsstrategien zu überdenken. Die etablierte strategische Positionierung der Kostenführerschaft scheidet in diesem Umfeld nahezu aus, da eine Differenzierung durch individuelle Leistungsangebote an den Kunden durch digitale Dienstleistungen deutlich attraktiver wird. Das bereits etablierte Konzept des Lösungsgeschäfts ist in Zeiten der digitalen Transformation der Unternehmen aktueller denn je und muss von Unternehmen umgesetzt werden.
Für Unternehmen bedeutet dies den oben genannten strategischen Wandel von einem reinen Sachgüterhersteller hin zu einem Lösungsanbieter mit individuellen Dienstleistungsangeboten.
Eine zentrale Herausforderung, um den Wandel erfolgreich zu gestalten, ist die Anpassung des Mitarbeiterverhaltens. Hier haben insbesondere kleine und mittlere Unternehmen (KMU) einen enormen Bedarf an Methoden, mit deren Hilfe die Transformation aufwandsarm und zielgerichtet begleitet wird.
Im Rahmen des Projekts wurde ein Vorgehen entwickelt, welches erstmals die Methoden des Behavioral Brandings in einen Managementansatz überführt, um eine zielgerichtete Anpassung des Mitarbeiterverhaltens bei der Transformation zum Lösungsanbieter zu gewährleisten. Dieses Buch entstand im Rahmen des Forschungsprojekts ‚fit4solution‘ des FIR an der RWTH Aachen gemeinsam mit dem Lehrstuhl für Marketing der RWTH Aachen und in der Zusammenarbeit mit kleinen und mittleren Unternehmen (KMU) aus dem Bereich der produzierenden Industrie. Ausgehend von dieser Zielsetzung wurde ein KMU-gerechter, interdisziplinärer Ansatz für das Management der Transformation vom Produzenten zum Lösungsanbieter entwickelt und in Form eines individuell konfigurierbaren Methodenbaukastens, eines auf KMU zugeschnittenen Rollout-Konzepts und eines Train-the-Trainer-Konzepts bereitgestellt.
In Germany’s transition to a more sustainable industrial landscape, electricity generated by wind turbines (WT) remains a mainstay of the energy mix. Operating and maintenance costs, which account for roughly 25% of electricity generation costs in onshore WTs make improvements of maintenance activities a key lever in the economic operation of WTs. Prescriptive maintenance is a possible approach for improved maintenance activities. It is a concept where asset condition data is used to recommend specific actions and has great potential for the operation of wind parks. However, especially small, but also large wind park operators, and maintenance service providers often struggle with the implementation of such a new maintenance approach. As a part of the research project ReStroK, a learning game has been developed to support the training and familiarization of maintenance technicians with the concepts and underlying principles of this maintenance approach. In this paper, the concept for the development of a learning game will be presented. Multiple scenarios for its usage and their corresponding requirements will be discussed and an overview over the game will be given.