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Institute
Return on Maintenance
(2018)
This presentation will show how the use of digital technology in the context of industry 4.0 can contribute to understanding maintenance as a value driver for manufacturing companies. In addition, principles that can help companies to maximize this "return on maintenance" for their maintenance organization and company will be presented.
Today, however, agility is seen more than ever as a critical success factor for companies. In times of an increasing degree of digital interconnection and minimum viable products, a mentality is entering the industrial service sector that has so far only been exemplified by Internet companies (e.g. Google): New products and especially digital services are developed in highly iterative processes. To this end, customers are involved in early test phases of development and provide feedback on individual functional modules, which – in contrast to the previous approach – are only gradually assembled into a market-ready “100 percent version”. But especially with the development of new digital services, companies must ensure more than ever that both the existing analog service business and the design of new digital services are geared to effectiveness and efficiency in order to meet the growing demands of customers and competitors.
To achieve this, companies must not only be familiar with the products currently on the market, but also master the entire product history, which in some cases goes back more than 30 years and varies greatly from one industry to another.
Today, maintenance exceeds this definition, it is significantly more.
In many companies, it plays the role of an incubator for development
and drives digital transformation forward. The very essence of
Industrie 4.0 is the optimisation of the flow of information within as
well as outside of a company to accelerate the adjustment of company
organisations in the context of increasing competitive pressure.
Because of the variety of interfaces, information and data that
is available as well as its service character, maintenance lends itself easily as the area of choice for a company to make Industrie 4.0 real. Whilst doing so, the aim is not to equip employees with the
latest “gimmick“ for order processment or to be the company with
the highest number of lighthouse projects. Instead, maintenance
ensures reliable and cost-efficient production and, consequently,
the primary creation of added value of the manufacturing company.
Those who were identified as top performers during the “Smart
Maintenance“ consortium benchmarking by FIR at RWTH Aachen
University gain particular useful ideas twice as often as other follower companies directly from staff, thus releasing the right potential.
Information and data help to reach these goals and transfer the
vision of smart maintenance into actual pratice. But what is smart
maintenance exactly and how far along are you in the development
of your individual smart maintenance concept?
The FIR at the RWTH Aachen University continuously develops the concept and the principles of RoM further. It is already noticeable that the gap between companies that began preparing their maintenance departments for Industrie 4.0 years ago and those that are still struggling with the mere foundations of a professional maintenance organisation is rapidly increasing.
The first driver of the development sparked by Industrie 4.0 is the collection of and work with condition data. It is used to create a digital shadow of a service, e.g. maintenance measures in a specific
context. In the future, critical machine functions will be monitored continuously within production processes.
Based on these observations, the likelihood of machine failures can be predicted, which makes it possible to prioritize data-based maintenance measures. This means that maintenance activities, i.e. production plans, are based on prognoses regarding machine failures. By doing so, the currently existing separation between inspection, maintenance and reactive measures can be overcome, resulting in a holistic approach to maintenance. Maintenance specialists receive support from assistance systems, which give them access to all relevant information (e.g. machine history, spare part availability, proposals for measures, etc.). As a result, they can take on routine tasks in different areas as well and contribute to the increased flexibility of the production process. Although data is becoming an increasingly important driver of successful maintenance strategies,
maintenance employees continue to be central to specific tasks, machines and systems. In the future, it can be expected that they choose to become experts in a certain field and, ideally, actively share their knowledge with others within an open maintenance culture. Systems for interdisciplinary collaboration will be made part of everyday practice.
The maintenance department will be a center and distributor of knowledge in the agile company of the future.Only through the interaction of the outlined success principles, which amount to a paradigm shift within the maintenance department, the potential
benefit of maintenance as defined by RoM can be fully exploited, creating a long-term competitive advantage for those who consistently follow the path towards Industrie 4.0 in maintenance.
Industrie 4.0 is said to have major positive effects on productivity in manufacturing companies. However, these effects are not visible yet. One reason for this is the lack of understanding of maintenance services as a crucial value contributing partner in production processes, although scientific literature already highlighted the importance of indirect maintenance costs. In order to retrieve the unused potential of maintenance services, a digital shadow in form of a sufficiently precise digital representation is required, providing a data model for the value of maintenance actions so that asset and maintenance strategies can be optimized later on. Using case study research for process manufacturers, the first research contribution of this paper consists of 21 value contributing elements being identified. The second contribution is a reference processes model, showing seven major process steps as well as the required intra-organization interaction on an information technology system level. Therefore, it provides the base for the missing data model shaping the targeted digital shadow of maintenance services’ value contribution. [https://link.springer.com/chapter/10.1007/978-3-030-57993-7_69]