Abstract
In manufacturing processes, root cause analysis of tools’ failures is crucial to determine the system reliability and to derive cost minimizing strategies. Condition-based maintenance (CBM) is one of the relevant policies to reduce costs of tools usage subjected to degradation processes. In a previous work, the authors introduced a new statistical methodology entitled Generalized Fault Tree (GFT) analysis that demonstrated good results for reliability analysis and root cause analysis. In this work, we propose a new dynamic CBM methodology, through real-time failure forecasting of the replacement instant of friction welding tools at a Bosch TermoTechnology facility, based on the dynamic update of the GFT root probability. The GFT structure is described by data-driven basic events (BEs), obtained from an embedded accelerometer, and the tree that best describes the tools’ failures is obtained through a new training process that employs a pruning technique to reduce computational complexity. The results show that we can reduce at least 12% of the costs per welding cycle by applying the GFT approach and CBM, when compared with the current policy of preventive maintenance in (optimized) constant cycles replacement periods.
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Acknowledgments
The present study was partially developed in the scope of the Project Augmented Humanity (PAH) [POCI-01-0247- FEDER-046103], financed by Portugal 2020, under the Competitiveness and Internationalization Operational Program, the Lisbon Regional Operational Program, and by the European Regional Development Fund. The first author has a PhD grant supported FCT - Fundação para a Ciência e a Tecnologia, I.P. for the PhD grants ref. 2020.06926.BD. The second author was partially supported by the Center for Research and Development in Mathematics and Applications (CIDMA), through the Portuguese Foundation for Science and Technology, reference UIDB/04106/2020. The first and fourth authors would like to acknowledge the University of Aveiro, FCT/MCTES for the financial support of TEMA research unit (FCT Ref. UIDB/00481/2020 & UIDP/00481/2020) and CENTRO01- 0145-FEDER-022083 - Regional Operational Program of the Center (Centro2020), within the scope of the Portugal 2020 Partnership Agreement, through the European Regional Development Fund. The third author was supported by Bosch Termotecnologia, SA.
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The data sets used in this work are confidential information of Bosch company manufacturing system, so they are not publicly available.
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Nunes, P., Rocha, E.M., Neves, J., Santos, J. (2022). Real-Time Condition-Based Maintenance of Friction Welding Tools by Generalized Fault Trees. In: Guarda, T., Portela, F., Augusto, M.F. (eds) Advanced Research in Technologies, Information, Innovation and Sustainability. ARTIIS 2022. Communications in Computer and Information Science, vol 1675. Springer, Cham. https://doi.org/10.1007/978-3-031-20319-0_31
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