A simulation model of the optimal maintenance strategy: conceptual agent-based approach

In this Master’s thesis agent-based modeling has been used to analyze maintenance strategy related phenomena. The main research question that has been answered was: what does the agent-based model made for this study tell us about how different maintenance strategy decisions affect profitability of equipment owners and maintenance service providers? Thus, the main outcome of this study is an analysis of how profitability can be increased in industrial maintenance context. To answer that question, first, a literature review of maintenance strategy, agent-based modeling and maintenance modeling and optimization was conducted. This review provided the basis for making the agent-based model. Making the model followed a standard simulation modeling procedure. With the simulation results from the agent-based model the research question was answered. Specifically, the results of the modeling and this study are: (1) optimizing the point in which a machine is maintained increases profitability for the owner of the machine and also the maintainer with certain conditions; (2) time-based pricing of maintenance services leads to a zero-sum game between the parties; (3) value-based pricing of maintenance services leads to a win-win game between the parties, if the owners of the machines share a substantial amount of their value to the maintainers; and (4) error in machine condition measurement is a critical parameter to optimizing maintenance strategy, and there is real systemic value in having more accurate machine condition measurement systems.

A New Approach for Real Time Fault Diagnosis in Induction Motors Based on Vibration Measurement

Condition monitoring is used to increase machinery availability and machinery performance, reducing consequential damage, increasing machine life, reducing spare parts inventories, and reducing breakdown maintenance. An efficient real time vibration measurement and analysis instruments is capable of providing warning and predicting faults at early stages. In this paper, a new methodology for the implementation of vibration measurement and analysis instruments in real time based on circuit architecture mapped from a MATLAB/Simulink model is presented. In this study, signal processing applications such as FIR filters and fast Fourier transform are treated as systems, which are implemented in hardware using a system generator toolbox, which translates a Simulink model in a hardware description language - HDL for FPGA implementations.

Diagnóstico automático de falhas em grupos geradores hidroelétricos utilizando técnicas preditivas de manutenção e redes neurais artificiais

Pós-graduação em Engenharia Mecânica - FEIS

Evaluation of Condition Scoring of Feeder Calves as a Tool for Management and Nutrition

Two experiments were conducted to evaluate the effects of body condition scores of beef calves on performance efficiency and carcass characteristics. In Experiment 1, 111 steer calves were stratified by breed and condition score (CS) and randomly allotted to 14 pens. The study was analyzed as a 2 x 3 factorial design, with two breeds (Angus and Simmental) and three initial CS (4.4, 5.1, and 5.6). In Experiment 2, 76 steer calves were allotted to six pens by CS. The resultant pens averaged 3.9, 4.5, 4.7, 5.0, 5.1, and 5.6 in CS. Calves in both studies were fed a corn-based finishing diet formulated to 13.5% crude protein. All calves were implanted with Synovex- SÒ initially and reimplanted with Revalor-SÒ. In Experiment 1, 29-day dry matter intake (lb/day) increased with CS (17.9, 18.1, and 19.1 for 4.4, 5.1, and 5.6, respectively; p < .04). Daily gain (29 days) tended to decrease with increasing CS (4.19, 3.71, and 3.26; p < .13). Days on feed decreased with increasing CS (185, 180, and 178d; p < .07). In Experiment 2, daily gains also increased with decreasing initial CS for the first 114 days (p < .05) and tended to increase overall (p < .20). In Experiment 1, calves with lower initial CS had less external fat at slaughter (.48, .53, and .61 in. for CS 4.4, 5.1, and 5.6, respectively; p < .05). This effect was also noted at slaughter (p < .10), as well as at 57 days (p < .06) and at 148 days (p < .06) as measured by real-time ultrasound. Measurements of intramuscular fat and marbling were not different in either study. These data suggest that CS of feeder calves may be a useful tool for adjusting energy requirements of calves based on body condition. Also, feeder cattle may be sorted into outcome or management groups earlier than currently practiced using body condition and/or real-time ultrasound.

Vibration based health monitoring of civil infrastructure using energy harvesting techniques

The use of structural health monitoring of civil structures is ever expanding and by assessing the dynamical condition of structures, informed maintenance management can be conducted at both individual and network levels. With the continued growth of information age technology, the potential arises for smart monitoring systems to be integrated with civil infrastructure to provide efficient information on the condition of a structure. The focus of this thesis is the integration of smart technology with civil infrastructure for the purposes of structural health monitoring. The technology considered in this regard are devices based on energy harvesting materials. While there has been considerable focus on the development and optimisation of such devices using steady state loading conditions, their applications for civil infrastructure are less known. Although research is still in initial stages, studies into the uses associated with such applications are very promising. Through the use of the dynamical response of structures to a variety of loading conditions, the energy harvesting outputs from such devices is established and the potential power output determined. Through a power variance output approach, damage detection of deteriorating structures using the energy harvesting devices is investigated. Further applications of the integration of energy harvesting devices with civil infrastructure investigated by this research includes the use of the power output as a indicator for control. Four approaches are undertaken to determine the potential applications arising from integrating smart technology with civil infrastructure, namely • Theoretical analysis to determine the applications of energy harvesting devices for vibration based health monitoring of civil infrastructure. • Laboratory experimentation to verify the performance of different energy harvesting configurations for civil infrastructure applications. • Scaled model testing as a method to experimentally validate the integration of the energy harvesting devices with civil infrastructure. • Full scale deployment of energy harvesting device with a bridge structure. These four approaches validate the application of energy harvesting technology with civil infrastructure from a theoretical, experimental and practical perspective.

A Microdata Analysis Approach to Transport Infrastructure Maintenance

Maintenance of transport infrastructure assets is widely advocated as the key in minimizing current and future costs of the transportation network. While effective maintenance decisions are often a result of engineering skills and practical knowledge, efficient decisions must also account for the net result over an asset's life-cycle. One essential aspect in the long term perspective of transport infrastructure maintenance is to proactively estimate maintenance needs. In dealing with immediate maintenance actions, support tools that can prioritize potential maintenance candidates are important to obtain an efficient maintenance strategy. This dissertation consists of five individual research papers presenting a microdata analysis approach to transport infrastructure maintenance. Microdata analysis is a multidisciplinary field in which large quantities of data is collected, analyzed, and interpreted to improve decision-making. Increased access to transport infrastructure data enables a deeper understanding of causal effects and a possibility to make predictions of future outcomes. The microdata analysis approach covers the complete process from data collection to actual decisions and is therefore well suited for the task of improving efficiency in transport infrastructure maintenance. Statistical modeling was the selected analysis method in this dissertation and provided solutions to the different problems presented in each of the five papers. In Paper I, a time-to-event model was used to estimate remaining road pavement lifetimes in Sweden. In Paper II, an extension of the model in Paper I assessed the impact of latent variables on road lifetimes; displaying the sections in a road network that are weaker due to e.g. subsoil conditions or undetected heavy traffic. The study in Paper III incorporated a probabilistic parametric distribution as a representation of road lifetimes into an equation for the marginal cost of road wear. Differentiated road wear marginal costs for heavy and light vehicles are an important information basis for decisions regarding vehicle miles traveled (VMT) taxation policies. In Paper IV, a distribution based clustering method was used to distinguish between road segments that are deteriorating and road segments that have a stationary road condition. Within railway networks, temporary speed restrictions are often imposed because of maintenance and must be addressed in order to keep punctuality. The study in Paper V evaluated the empirical effect on running time of speed restrictions on a Norwegian railway line using a generalized linear mixed model.

Aplicação de ferramentas de simulação estocástica na área de planeamento de uma empresa de abastecimento de água

No presente trabalho procura-se evidenciar algumas soluções para aplicação de simulação estocástica num contexto de gestão dos ativos, aplicado a um sistema de abastecimento de água, tirando partido da informação disponível sobre a manutenção que vem realizando, ao longo dos anos. Procura-se também descrever como estas metodologias podem ser aplicadas noutros casos, futuramente, beneficiando ainda da recolha de informação de colaboradores da empresa, com experiência no cargo e com elevado conhecimento do funcionamento das infraestruturas. A simulação estocástica é uma área cujas ferramentas podem dar uma preciosa ajuda no processo de tomada de decisão. Por outro lado, as organizações preocupam-se, cada vez mais, com o tema da gestão de ativos e com os custos a si associados, começando a investir mais tempo e dinheiro nessa matéria com o objetivo de delinearem estratégias para aumentar o período de vida útil dos seus ativos e otimizarem os seus investimentos de renovação. Nesse contexto, evidencia-se que um adequado plano de intervenções de manutenção e operação é uma boa metodologia, para garantir a redução de falhas no sistema de abastecimento de uma empresa desse setor, bem como garantir que as infraestruturas se encontram em condições de funcionamento. Contudo, esta abordagem tradicional não será suficiente para garantir as melhores práticas e os objetivos que se pretendem alcançar com uma gestão de ativos atual. O trabalho inclui, ainda, um estudo de caso com que se aplicaram as ferramentas estudadas a um caso real de um grupo de bombagem, de uma das Estações Elevatórias da empresa.

Sistema de predição de avarias em máquinas de unidades fabris globalmente dispersas

Tese de Doutoramento Ramo Engenharia Industrial e de Sistemas

Comparison of tests for the detection of circulating filarial antigen (Og4C3-ELISA and AD12-ICT) and ultrasound in diagnosis of lymphatic filariasis in individuals with microfilariae

Significant advances were made in the diagnosis of filariasis in the 1990s with the emergence of three new alternative tools: ultrasound and tests to detect circulating antigen using two monoclonal antibodies, Og4C3 and AD12-ICT-card. This study aimed to identify which of these methods is the most sensitive for diagnosis of infection. A total of 256 individuals, all male and carrying microfilariae (1-15,679 MF/mL), diagnosed by nocturnal venous blood samples, were tested by all three techniques. The tests for circulating filarial antigen concurred 100% and correctly identified 246/256 (96.69%) of the positive individuals, while ultrasound detected only 186/256 (73.44%). Of the circulating antigen tests, ICT-card was the most convenient method for identification of Wuchereria bancrofti carriers. It was easy to perform, practical and quick.

Kunnossapidon kehitysmalli sanomalehtipainon tuotannon luotettavuuden, tuottavuuden ja tuotteen laadun turvaamiseksi

Diplomityössä käsitellään ne toimet, jotka Esa Lehtipaino Oy:ssä tarvitsee tehdä kunnossapidon kehittämiseksi sanomalehtipainoprosessin kunnossapidossa. Työssä käytettiin luotettavuuskeskeisen ja kokonaisvaltaisen tuottavuuskeskeisen kunnossapidon strategioiden osia sekä PSK Standardisoinnin PSK 5705:2006standardin mukaista menetelmää määrittämään kunnossapidon kannalta tärkeimmät kohteet ja osa-alueet. PSK 5705:2006 on kunnonvalvonnan värähtelymittausten mittaustoiminnan suunnitteluun luotu standardi, jonka perusteella rakennettiin sanomalehtipainoprosessiin sopiva tuotantolaitteiston luokitusjärjestelmä. Luokituksenperusteella kohdennetaan kunnossapidon resurssit tuotantojärjestelmän luotettavuuden kannalta oikeisiin, tuottavimpiin kohteisiin. Tuotantohenkilöstön kunnossapitohenkilökunnalle tekemien vikailmoitusten välitykseen rakennettiin Microsoft Access -pohjainen Vikaloki-lomake. Kunnossapitotoiminnan kehityksen tuloksien seuraamiseksi määritettiin PSK 6201:2003 standardin mukainen tuotannon kokonaistehokkuutta kuvaava KNL-luku. KNL-luvusta luotiin ennuste kunnossapidon kehittämistarpeista regressioanalyysin avulla. Kehitysmalli esittää, että kohdeyrityksessä tulee toiminnan kehittäminen aloittaa päivittämällä tietokonepohjainen toiminnanohjausjärjestelmä, johon lisätään ennakoivat suunnitellut kunnossapitotoimet. Toimet määriteltiin yllämainitun kriittisyysluokituksen perusteella.

Venttiilien kunnossapidon optimointi

Tässä työssä tarkastellaan venttiilien kunnossapitoa ja erityisesti niiden kunnonvalvontaa. Työssä on kerrottu perusteita venttiileiden kunnonvalvonnan suorittamiseksi, venttiili- ja toimilaitevikojen perussyistä ja niiden havaitsemisesta. Työn pääpaino on kuitenkin kunnonvalvontamenetelmissä ja niiden käytössä. Mittauksia venttiilivuodon havaitsemiseksi suoritettiin akustisen emission, ultraäänen ja lämpötilan pistemittauksen avulla. Venttiilien yleistä kuntoa määritettiin värähtelyn, venymäliuskojen ja laitoksella jo toimivan moottoritoimilaitteen virtamittauksen avulla. Työssä on annettu suuntaviivat tulosten tulkitsemiselle, mutta yksityiskohtainen ja tarkempi tulosten tulkinnan määrittäminen jätetään laitoksen henkilökunnasta sille henkilölle joka mittauksia tulee tekemään tai jonka työnkuvaan muuten kuuluu kyseisten tulosten tulkitseminen.

Data collection and criticality analysis for cost effective maintenance during the life cycle of a flue gas line

Työn tarkoituksena oli kerätä käyttövarmuustietoa savukaasulinjasta kahdelta suomalaiselta sellutehtaalta niiden käyttöönotosta aina tähän päivään asti. Käyttövarmuustieto koostuu luotettavuustiedoista sekä kunnossapitotiedoista. Kerätyn tiedon avulla on mahdollista kuvata tarkasti laitoksen käyttövarmuutta seuraavilla tunnusluvuilla: suunnittelemattomien häiriöiden lukumäärä ja korjausajat, laitteiden seisokkiaika, vikojen todennäköisyys ja korjaavan kunnossapidon kustannukset suhteessa savukaasulinjan korjaavan kunnossapidon kokonaiskustannuksiin. Käyttövarmuustiedon keräysmetodi on esitelty. Savukaasulinjan kriittisten laitteiden määrittelyyn käytetty metodi on yhdistelmä kyselytutkimuksesta ja muunnellusta vian vaikutus- ja kriittisyysanalyysistä. Laitteiden valitsemiskriteerit lopulliseen kriittisyysanalyysiin päätettiin käyttövarmuustietojen sekä kyselytutkimuksen perusteella. Kriittisten laitteiden määrittämisen tarkoitus on löytää savukaasulinjasta ne laitteet, joiden odottamaton vikaantuminen aiheuttaa vakavimmat seuraukset savukaasulinjan luotettavuuteen, tuotantoon, turvallisuuteen, päästöihin ja kustannuksiin. Tiedon avulla rajoitetut kunnossapidon resurssit voidaan suunnata oikein. Kriittisten laitteiden määrittämisen tuloksena todetaan, että kolme kriittisintä laitetta savukaasulinjassa ovat molemmille sellutehtaille yhteisesti: savukaasupuhaltimet, laahakuljettimet sekä ketjukuljettimet. Käyttövarmuustieto osoittaa, että laitteiden luotettavuus on tehdaskohtaista, mutta periaatteessa samat päälinjat voidaan nähdä suunnittelemattomien vikojen todennäköisyyttä esittävissä kuvissa. Kustannukset, jotka esitetään laitteen suunnittelemattomien kunnossapitokustannusten suhteena savukaasulinjan kokonaiskustannuksiin, noudattelevat hyvin pitkälle luotettavuuskäyrää, joka on laskettu laitteen seisokkiajan suhteena käyttötunteihin. Käyttövarmuustiedon keräys yhdistettynä kriittisten laitteiden määrittämiseen mahdollistavat ennakoivan kunnossapidon oikean kohdistamisen ja ajoittamisen laitteiston elinaikana siten, että luotettavuus- ja kustannustehokkuusvaatimukset saavutetaan.

The Design of a Software Lifecycle Management Framework to a Configuration Management System

Keeping track of software assets and managing software installations in IT environments can be a hard endeavor, especially when the size and diversity of the environment grows. How to install and uninstall software efficiently and cost effectively? Are there too few or too many software licenses purchased? If installed, is the software actually in use? Software Asset Management (SAM) is a process that involves managing and optimizing the purchase, deployment, maintenance, utilization, and disposal of software applications within an organization. This master’s thesis describes a special Software Lifecycle Management Framework to provide solutions to the multitude of challenges within SAM. The main objectives when designing the framework was to provide a set of tools to control the software assets during their entire lifecycle while trying to minimize the costs related to owning and managing them.

Kunnonvalvonnan uudelleen organisointi

Tutkimuksen tavoitteena oli tarkastella nykyinen kunnonvalvonnan toimintomalli Eforan kunnossapitopaikkakunnilla. Tarkastelun pohjalta tutkimuksessa organisoidaan kunnonvalvonta uudelleen näissä kohteissa. Kohteena ovat Eforan paikkakunnat Heinola, Imatra, Oulu, Varkaus, Veitsiluoto is Uimaharju. Teoriaosiossa käsitellään strategista johtamista yrityksen perustamisen näkökulmasta, Perustamista lähestytään myös analyysien kautta, sekä organisaation liiketoimintamallien ja prosessien kautta. Empiirisessä osiossa tehtiin organisaation hahmottamisen kautta portfolio-analyysi, markkinatarkastelu is toimintasuunnitelma. Ne loivat perustan uudelleen organisoitumiselle. Osioon sisältyvät myös toiminnan käynnistämiseen, järjestäytymiseen, mittaamiseen, seurantaan ja raportointiin liittyvät toimet.

Online Ultrasound Measurements of Membrane Compaction

There are several filtration applications in the pulp and paper industry where the capacity and cost-effectiveness of processes are of importance. Ultrafiltration is used to clean process water. Ultrafiltration is a membrane process that separates a certain component or compound from a liquid stream. The pressure difference across the membrane sieves macromolecules smaller than 0.001-0.02 μm through the membrane. When optimizing the filtration process capacity, online information about the conditions of the membrane is needed. Fouling and compaction of the membrane both affect the capacity of the filtration process. In fouling a “cake” layer starts to build on the surface of the membrane. This layer blocks the molecules from sieving through the membrane thereby decreasing the yield of the process. In compaction of the membrane the structure is flattened out because of the high pressure applied. The higher pressure increases the capacity but may damage the structure of the membrane permanently. Information about the compaction is needed to effectively operate the filters. The objective of this study was to develop an accurate system for online monitoring of the condition of the membrane using ultrasound reflectometry. Measurements of ultrafiltration membrane compaction were made successfully utilizing ultrasound. The results were confirmed by permeate flux decline, measurements of compaction with a micrometer, mechanical compaction using a hydraulic piston and a scanning electron microscope (SEM). The scientific contribution of this thesis is to introduce a secondary ultrasound transducer to determine the speed of sound in the fluid used. The speed of sound is highly dependent on the temperature and pressure used in the filters. When the exact speed of sound is obtained by the reference transducer, the effect of temperature and pressure is eliminated. This speed is then used to calculate the distances with a higher accuracy. As the accuracy or the resolution of the ultrasound measurement is increased, the method can be applied to a higher amount of applications especially for processes where fouling layers are thinner because of smaller macromolecules. With the help of the transducer, membrane compaction of 13 μm was measured in the pressure of 5 bars. The results were verified with the permeate flux decline, which indicated that compaction had taken place. The measurements of compaction with a micrometer showed compaction of 23–26 μm. The results are in the same range and confirm the compaction. Mechanical compaction measurements were made using a hydraulic piston, and the result was the same 13 μm as obtained by applying the ultrasound time domain reflectometry (UTDR). A scanning electron microscope (SEM) was used to study the structure of the samples before and after the compaction.