Journal of International Technology and Information Management

Volume 15 Issue 4 Article 2

2006

Mobile Maintenance Management

Aitor Arnaiz
Fundacion Tekniker, Spain

Christos Emmanouilidis
CETI/ATHENA Research & Innovation Centre in Information Communication & Knowledge, Greece

Benoit Iung
Nancy University, France

Erkki Jantunen
VTT Technical Research Centre of Finland, Finland

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Management," Journal of International Technology and Information Management: Vol. 15 : Iss. 4 , Article
2.
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Mobile Maintanence Management Journal of International Technology and Information Management

Mobile Maintenance Management

Aitor Arnaiz
Fundación Tekniker, Spain

Christos Emmanouilidis
CETI/ATHENA Research & Innovation Centre in
Information Communication & Knowledge, Greece

Benoit Iung
Nancy University, France

Erkki Jantunen
VTT Technical Research Centre of Finland, Finland

ABSTRACT

The paper gives a short overview of the enabling tools and technology available to the
maintenance engineer in manufacturing industry, in relation to the emergence of e-maintenance practices
and the introduction of mobile computing devices. An analysis of the main characteristics of the e-
maintenance concepts and the associated challenges is provided, highlighting the lack of use of
condition-based maintenance strategies. The potential of using ubiquitous computing in industrial
maintenance practice is then examined, followed by an original vision for the adoption of mobile
maintenance management solutions, which can facilitate the implementation of condition-based-
maintenance. This vision is supported today by the European Integrated Project DYNAMITE 017498
(Dynamic Decisions in Maintenance).

INTRODUCTION

Today maintenance is going through major changes. The industry and also the public are realising that the
efficient use of industrial assets is a key issue in supporting our current standard of living. In this context, efficiency
means producing good quality products without interrupting the production for unnecessary breakdowns.

With current ever growing demand for improvements on system productivity, availability and safety,
product quality, customer satisfaction and taking into account the trend for decrease in profit margins, the
importance of implementing efficient maintenance strategies becomes unquestionable. In this setting the
maintenance function plays a critical role in a company’s ability to compete on the basis of cost, quality and delivery
performance and maintenance is taken into account in production requirements (Al-Najjar & Alsyouf, 2003; Crespo
& Gupta, 2006; Pinjal et al., 2005). For example, studies over the last 20 years have indicated that around Europe,
the indirect cost of maintenance is equivalent to between 4% and 8% of total sales turnover (similar amount as for
the direct cost). Thus, in the countries where modern maintenance practices have yet to be well adopted by industry,
the potential savings from modern maintenance are massive. These modern and efficient maintenance practices
involve, at least, the identification of the root-cause of component failures, reduction of production systems failures,
elimination of costly unscheduled shutdown maintenances, and ultimately an improvement both in productivity as
well as in product quality.

At the very end of this changing focus on maintenance there exists a new role for the maintenance function,
particularly for the manufacturing industry, taking into account a life-cycle management oriented approach. Here,
limits on resources and energy consumption will invoke a sharp change in the objectives of manufacturing, shifting
from the need to produce more efficiently, to the need to actually produce new assets as late as possible, while

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A. Armaiz, C. Emmanouilidis, B. Iung & E. Jantunen 2006 Volume 15, Number 4

ensuring customer satisfaction and profits. In this manufacturing paradigm shift, a new culture wherein maintenance
activities become of equal importance to actual production activities, is becoming highly relevant (Takata et al.,
2004).

To support this role, the maintenance concept has undergone through several major developments
involving proactive considerations, which require changes in transforming traditional “fail and fix” maintenance
practices to “predict and prevent” e-maintenance strategies. Such an approach takes into account the potential
impact on service to customer, product quality and cost reduction (Lee 2004). The key advantage is that
maintenance is performed only when a certain level of equipment deterioration occurs rather than after a specified
period of time or usage. In other words, there is a shift away from current mean-time-between failure (MTBF)
practices to mean-time-between-degradation (MTBD) technologies. E-Maintenance provides the opportunity for the
3rd generation maintenance and is a sub-concept of e-manufacturing and e-business for supporting next generation
manufacturing practices (NGMS).

One key support factor of this 3rd generation maintenance is the concept of mobile devices or mobile
agents, offering the flexibility to initiate applications at flexible locations in unstructured networked environments,
to quickly and efficiently search for and retrieve relevant information (i.e., on component or equipment degradation)
from heterogeneous data sources, to perform tasks and to provide asynchronous services to client requests. For
example, personal digital assistants (PDA) devices play a key role in bringing Mobile Maintenance Management
closer to the daily practice at the shop floor. The PDAs enable the maintenance personnel to directly gain
information from monitored machinery i.e. what is the current state, which maintenance actions have been carried
out on them and how future necessary maintenance actions should be carried out.

WHAT IS E-MAINTENANCE?

Baldwin (2004) proposes to define e-maintenance as “The network that integrates and synchronises the
various maintenance and reliability applications to gather and deliver asset information where it is needed. E-
maintenance is a subset of e-manufacturing and e-business”. In accordance with the notion of integration and
synchronisation, the Intelligent Maintenance Centre defined e-maintenance as “the ability to monitor plant floor
assets, link the production and maintenance operations systems, collect feedbacks from remote customer sites, and
integrate it to upper level enterprise applications”. A more general definition is “maintenance management concept
whereby assets are monitored and managed over the Internet”. Indeed Internet regarded as a new technology, have
led for some companies to replace conventional reactive strategy by proactive vs. aggressive strategies as shown by
Swanson (2001).

It is shown by Iung (2003) that in that way, e-maintenance is integrating the principles already
implemented by tele-maintenance, which are added to the web-services and collaboration principles. Collaboration
allows not only to share and exchange information but also knowledge and (e)-intelligence (new services, new
processing). By means of a collaborative environment, pertinent knowledge and intelligence become available and
usable to the right place, at the right time, in order to facilitate reaching the best maintenance decisions all along the
product life cycle (design, manufacturing, use, end-of life). The distance between actors is now measurable in
“network intelligence power” rather than in thousand of miles (Ulieru et al., 2000). Thus, with the use of Internet,
web-enabled and wireless communication technology, e-maintenance is transforming manufacturing companies to a
business service to support their customers anywhere and anytime.

Leger et al., (1999) point out that some companies (such as General Motors, Canon, Rockwell, etc.) have
been investigating e-maintenance for several years now and have already adopted it with significant impact on
business process changes. Some e-maintenance platforms such as ENIGMA, TELMA, ICAS, PROTEUS, CASIP …
exist, where the resulting e-maintenance infrastructure replaces the conventional hierarchical structure by a
heterarchical or intelligent one as advocated by the IMS (Intelligent Manufacturing Systems) worldwide initiative
(Yoshikawa 1995). Such an infrastructure is adding “intelligence” to components through Infotronics and extensive
use of distributed agent technology (Lee 2004). It entails several networks for supporting not only the exchanges
between the enterprise and its external relationships (e.g., CRM) but also real-time communication between devices,
machinery and computing equipment at different Enterprise levels (ERP, MES).

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Mobile Maintanence Management Journal of International Technology and Information Management

In general, the e-maintenance view supplements the ERP in managing the risk associated with “faulty”
performance, and the MES in anticipating (and reacting) as fast as possible to progressing degradation (and failure)
of the manufacturing processes. Thus, the maintenance information system (i.e., the computerised maintenance
management system (CMMS) and the computerised maintenance operational system CMOpS) is strongly related to
the ERP/MES in supporting condition based maintenance (CBM) and predictive maintenance (PdM). Based on this
relevance, different layers of the e-maintenance architecture () can be defined (Yu et al., 2003):

• A maintenance decisional layer allowing on the one hand the definition of the
maintenance policy applied equipment, in accordance with the Enterprise policy, and on the other hand
supporting staff management and the purchase management related to spare part. This layer could be
considered as STRATEGIC level.

• A maintenance management layer where the CMMS aims at “deploying” the

maintenance policy selected at the decisional level. In collaboration with the manufacturing area, it plans
the interventions required to maintain the system and ensures the logistics support. i.e. the resources,
services and management means necessary to the maintenance intervention execution. Today, the
maintenance functions implemented at this level through CMMS have to be vertically integrated with the
ERP solution in accordance with part 1 and 2 of the ANSI/ISA SP95 standard (IEC/ISO62264). This layer
could be considered as TACTICAL level.

• A maintenance operational (local) layer implemented by the integration of the

CMMS with all the MES functions (part 3 and 4 of the ANSI/ISA SP95) and by linking the “Computerised
Maintenance Operational System” with field tools and field components such as condition monitoring
tools, PLCs, sensors and actuators (Léger 2004). The goal of the maintenance function at this level is (a) to
check the availability state and degradation status of each component in order to master system
performance, (b) to give support and assistance to the operator for degradation vs. failure diagnosis and
then for preventive and/or corrective action deployment, and (c) to calculate performance indicators related
to system functioning from data provided by field components. Nevertheless, some of these components
can already support “basic” maintenance functions in the case of smart components deploying processing
capabilities (i.e. instrumentation with field bus interface and internal memory and processing). This layer
could be considered as OPERATIONAL level.

Figure 1. Maintenance layers within Enterprise organisation.

(a) Horizontal Integration

ISA-SP95 part 3 & 4
(b) Vertical Integration ERP
ERP
ISA-SP95 part 1&2

(b)
(b)
(a) CMMS
CMMS

MES
Sensors PDA
Smart Sensors CMOpS PLCs …

CHALLENGES IN E-MAINTENANCE

On each of these maintenance layers, various actors (or agents) have been assigned responsibilities for
fulfilling the expected Maintenance services. In order to implement these services, the actors have to exchange
heterogeneous information, which varies in content, as well as transmission characteristics. Taking into account the

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geographical spread of these actors in the Enterprise environment (distributed architecture; different hierarchical
layers), the information exchanges require communication support, such as office networks dedicated for
management-level issues and industrial networks for production and execution-level issues. The main differences
between these two types of networks arise at the lower production levels (i.e., field components levels). In that way,
wireless technologies may provide considerable savings in networking cost and degree of flexibility not met in
wired systems (Egea-Lopez et al., 2005). The choice of the communication (wireless or not) is related to the
constraints/benefits it can bring according to the actors features and the relationships between actors required for
supporting maintenance application.

Some of these items can be described as follows:

• The degree of mobility asked by the actor. A PDA-equipped actor must act at
different geographical locations on site and must be able to be connected easily to the field components,
necessary to carry out the maintenance work-order. On the other hand, the CMMS can physically reside in
the main office (data office), containing the central maintenance-related Data Base (linked to the ERP
database).

• The distance between actors. A very short distance between actors (intra-layer
interactions) facilitates the implementation of wireless technology whereas a long distance between actors
(inter-layers interactions; interactions between companies) supports the deployment of traditional wired
networks. For Wireless Technology, the distance can lead to develop infrastructure solution rather than ad-
hoc solution (or vice versa) (Remondo & Niemegeers, 2003).

• The type of service supported by each actor and thus the information content to be
transmitted, taking into account traffic conditions.

• The environment of the actors (i.e. industrial) and the constraints which are applied
to them (i.e., safety).

Most of the previous items are materialised in “the Roadmap for Network Technologies and Services”
(Alahuhta et al. 2004) by the concept of Multi-sphere reference model leading to identify current challenges in e-
maintenance.

Collaboration, web-services, e-Intelligence and Infotronics are key enabling factors for an e-maintenance
approach, which has well defined scientific foundations and industrial benefits. Indeed, the positive impact of e-
maintenance on productivity, sustainability and quality, has to be demonstrated to justify investments in this
emerging field. Thus as highlighted by (Iung & Crespo, 2006), future common industrial/academic working/research
directions address, but are not limited to:

• Incorporation of new technologies concerning “intelligent devices” such as micro-

electromechanical systems (MEMS), mobile computing devices and smart tags, to support remote
monitoring and diagnosis and for assessing component performance (i.e., IP project DYNAMITE 017498
and IP project SMMART (Smart, 2005)).

• Modelling and deployment of new services, such as e-monitoring, e-diagnosis, e-

prognosis and e-logistics, which require information from “intelligent devices” for helping maintenance
decision making according to system expected performances.

• Development of reliable data repositories that can improve the quality of decision
making process by statistical analysis of relevant information such as failure models, usage, etc.

• Extension of the e-maintenance services over the whole Product Life Cycle (to track
the product from birth to death) (i.e. IMS Project PROMISE (Kiritsis, 2004)).

• Developing theories and tools for describing, quantifying and optimising the

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Mobile Maintanence Management Journal of International Technology and Information Management

behaviour of the interactions of the system-maintenance-economy model (MME) and then developing
maintenance decision support systems (MDSS) for cost-effective decisions enhancing company’s
profitability and competitiveness continuously (Cost-effectiveness models).

• Modelling of interoperability requirements between all the e-maintenance services

(and software) and definition of ontologies formalizing the e-maintenance service semantics (i.e. IP project
DYNAMITE 017498, project PROTEUS (Bangemann et al., 2006), MIMOSA initiative (Machinery
Information Management Open System Alliance) – IEEE 1232, IEC/ISO62264 (Enterprise – Control
system Integration) based on ANSI/ISA S95).

• Development of new Infotronics-based e-maintenance systems offering integration

of distributed intelligent devices, services and maintenance software such as CMMS. It consist, for
example, in proposing new protocols for collaboration and negotiation, DAI techniques, maintenance
workflow, maintenance web Services (Venkatraman 2004), maintenance web semantic etc. but also proof
tools to verify the properties of the global functioning from each distributed items (i.e., Proof-oriented fault
system engineering).

• Adoption and incorporation of industrially relevant standards for wireless

networking, wireless ad-hoc sensor networks, and real-time and safety constraints (i.e., IEEE 802.11x,
IEEE 802.15.4, EN457:1992- ISO7731).

IP DYNAMITE: FLEXIBILITY AND MOBLITY TO FACE

CURRENT E-MAINTENANCE CHALLENGES

Clearly more research effort is required to face up to the challenges for modern e-maintenance. One
focused research direction is offered by the new EU-funded Integrated Project DYNAMITE - Dynamic Decisions in
Maintenance, coordinated by VTT Technical Research Centre of Finland. It includes six research institutes in the
UK, France, Spain, Sweden and Finland, two car manufacturers FIAT and Volvo, the machine tool manufacturer
Goratu, the automation and maintenance services provider Zenon, and seven SME’s representing related business
areas.

The main challenge that DYNAMITE faces is related to the lack of flexible and cost-efficient maintenance
systems also with current demands of flexible manufacturing systems in today’s manufacturing industries. This
challenge is related to many of the problems indicated above, but it is particularly linked to the low level of diffusion
that advanced maintenance strategies, such as condition based maintenance (CBM) and predictive maintenance
(PdM), have reached so far. According to Komonen (2005) about 30 % of all the maintenance activities in industrial
and transportation systems in Europe are unplanned, whereas a 55% of the activities are related to planned and
scheduled maintenance. That is, 85% of the maintenance strategies implies unnecessary action costs and machinery
breakdowns or service actions like disassembly that have negative effects on the performance and lifetime of
components. This leaves a maximum of 15% of the activities being focused on CBM strategies that presumably
accounts for the newer and more critical machinery, where cost-benefit ratio clearly favours condition-based
approaches.

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A. Armaiz, C. Emmanouilidis, B. Iung & E. Jantunen 2006 Volume 15, Number 4

Figure 2. The European DYNAMITE concept for future IT-based maintenance.

The DYNAMITE vision () aims at promoting a major change in the focus of condition based maintenance,
essentially taking full advantage of recent advanced information technologies related to hardware, software and
semantic information modelling. Special attention is also given to the identification of cost-effectiveness related to
the upgraded CBM strategies, as well as to the inclusion of innovative technologies within CBM. It is expected that
the combination of the use of new technologies with a clear indication of cost-benefit trade-off will facilitate the
upgrade into CBM, in many cases where non-critical machinery exists, and especially for the vast majority of SME
companies that feel the distance between planned maintenance and condition based is too wide.

The main technologies expected to facilitate this upgrade are wireless devices, such as smart tags and hand-
held computing devices, micro-size MEMS sensors especially designed for maintenance purposes, and low-cost on-
line lubrication analysis sensors. On the other hand, adequate information processing tools should take care of the
continuous data flow and suggest appropriate actions to the operators. In order to provide the most convenient
analysis flow, information processing is understood as a distributed and collaborative system, where three different
levels of entities can undertake intelligence tasks (). At the lower end, sensors can provide certain degree of
reasoning, taking into account the ‘local’ scope of this processing. At a medium level, smart PDAs (mobile agents)
will provide higher communication interfaces with sensors, intermediate processing capabilities and a smart end for
human interface to remote web services centres that will compose a distributed web platform system at the higher
end of the processing hierarchy. Finally, wireless data transmission between sensor devices and information
processing layers will be implemented.

As the complete DYNAMITE processing system is based on a distributed intelligence concept, is it clear
that sensors and smart tags should perform only those data processing tasks that may handle more efficiently than
upper intelligence layers. For instance, it is not in general easy to perform diagnosis at the sensor-level, as this
diagnosis will be partially compared to what can be offered by PDAs or web services. On the other hand, it is

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expected to have signal processing capabilities at the sensing devices in many cases, as this will release
communication throughput and computing resources for other tasks.

Also, given this global architecture, it is clear that the role of the mobile agent devices is very important
within the e-maintenance concept linked to DYNAMITE project. On the other hand, the distributed DYNAMITE
processing layers also pose some ‘system’ constraints on the use of such mobile agent devices. These should not act
at the highest end of intelligence, but rather as a web-platform mobile interface with built-in local intelligence and
inter-connected both with the central data-office, as well as with the monitored equipment, thus enabling
engineering personnel to perform fast and efficient maintenance activities at the shop floor.

Mobile devices in maintenance management

Since their inception (Chess et al., 1995), mobile agents have been used in a wide variety of applications.
There are several advantages in employing mobile computing compared to conventional wired computer
applications. Among other, mobile computing offers the flexibility to initiate applications at flexible locations in
unstructured networked environments, to quickly and efficiently search for and retrieve relevant information from
heterogeneous data sources, to perform tasks while utilising limited or intermittent connectivity and to provide
asynchronous services to client requests (Samaras, 2004). Adding the ease and flexibility of carrying a handheld
wireless device, mobile computing has the potential to transform the way a range of industrial management,
monitoring and control tasks are performed (Buse & Wu, 2004). This potential is still largely unexplored in
maintenance management.

Although the usage of wireless devices within an e-maintenance framework has been suggested in the past
(Lee, 2001), integrated maintenance management solutions based on combined usage of wireless sensing, RFID
tags, hand-held devices and central or remote server-side computing and data-offices (Lampe et al. 2004, Legner &
Thiesse, 2006, Wittenberg, 2003) are still in their infancy. Part of the difficulty is attributed to the challenge of
integrating equipment, devices and computing resources and code from very heterogeneous sources (Bartelt et al.,
2005, Trossen & Pavel, 2005) but also to the great complexity of optimising the management of maintenance in
modern industry.

Within DYNAMITE, the usage of PDA devices plays a key role in bringing Mobile Maintenance
Management closer to the daily practice at the shop floor. PDAs are used in synergy with intelligent sensing devices
and smart tags on the lower-end of the data processing architecture, but also with central server's databases and data
processing and remote access applications at the higher-end of the architecture. An example of the architecture
functionality is provided in .

Figure 3. An example of the architecture functionality centred PDA.

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A. Armaiz, C. Emmanouilidis, B. Iung & E. Jantunen 2006 Volume 15, Number 4

Server Infrastructure

PDA Data Server-side

SOAP / RPC
Analysis applicationsoftw are server KBS

Terminal
PDA GUI
Services
Technician

PDA Data
Server-side Historic and
Acquisition OPC ( DA -XMLDA )
data exchange Reference data
Interface
Database

Machinery

Tag Reader
sensing
agent Wireless Data Acquisition

RFID tag

Here the hand-held device is employed within a thin-client server architecture. The “mobile worker”
(technician), equipped with the PDA, approaches the monitored machinery. The PDA is equipped with an RFID tag-
reader enabling the automatic identification of the equipment/component and thus it becomes possible to
automatically retrieve relevant data from the central system (Historic and Reference data Database) and quickly
present it to the user. Furthermore, the PDA can access measurements logged to the intelligent sensing device
(sensing agent) and combine/compare those with the automatically retrieved related historical and reference data
from the central database, but also with domain knowledge from the central KBS (server KBS). Thus the PDA
becomes a ubiquitous expert advisor and, at the same time, a flexible data collector. Within this architecture there
can be several intelligent sensing devices, distributed across the plant, which can wirelessly transmit via short range
RF either directly or indirectly via data logger gateways from the shop floor. In this manner, instead of an inflexible
costly and rather inaccessible wired monitoring structure, we have a flexible, easy to deploy and operate wireless e-
maintenance architecture, which can become a powerful, efficient and easy to use tool for the maintenance engineer,
while at the same time can be integrated with the organisation ERP.

Functional range of available PDAs

Today there is a huge number of potential PDA hardware available. These can be divided into four
principal subgroups:

1. Regular consumer PDAs

2. Retail / Logistics PDAs
3. Smart Phone PDAs
4. Custom Reference Platforms

Their features vary considerably, as it is summarised in .

Table 1. Comparison of the four main PDA subgroups.

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Feature Regular Retail / Logistics Smart Phone Custom Reference

consumer PDAs PDAs Platforms
PDAs
1. Wireless 802.11 High-End Yes (option) Rare Yes
2. SR Wireless No (expansion) No (expansion) No (expansion) No (expansion)
3. RFID reader No (expansion) Extra Option No (expansion) No (expansion)
4. Barcodes No (expansion) Yes No No
5. Display (VGA) VGA QVGA QVGA VGA (some)
6. Keypad/AlphNum Some/Some Yes/Some Some/Some Yes
7. Pen/OSK Yes Yes Yes Yes
8. Web Browsing Yes Yes Yes Yes
9. Powerful CPU Yes(400+ MHz) Yes Some (~200MHz) Yes (400+MHz)
10. Java/.Net Some/Yes Some/Yes Yes / Yes Option
11. Rugged Case No Yes No Option
12. Battery Life No Yes Yes Option
13. Common OS Yes Yes Some Option
14. Expansion Slots Yes (one) Yes (1+) Some Option

Notes

As can be observed by the table above the platforms coming from the logistics – retail sector tend to be
richer in features, which are useful for industrial usage. Nonetheless, features which are still hard to find off the
shelf are: short range wireless, RFID and barcode reader (except retail sector PDAs) and also PDA expansion slot
availability. Such features are deemed important for mobile solutions tailored to serving industrial maintenance
management needs and customised PDAs are necessary for the implementation of the mobile maintenance
management concept.

CONCLUSION

In this paper the great changes of maintenance and its importance in supporting manufacturing industry
have been discussed. First a short overview of the enabling tools and technology available to the maintenance
engineer in manufacturing industry, in relation to the emergence of e-maintenance practices and the introduction of
mobile computing was provided. Furthermore, the concepts of e-maintenance have been covered. The challenges of
today's maintenance have been briefly described, highlighting a lack of industrial implementation of condition-based
maintenance strategies. The potential of using ubiquitous computing in industrial maintenance practice has been
discussed, followed by an outline of our vision for the adoption of mobile maintenance management solutions. This
vision is supported today by the European Integrated Project DYNAMITE 017498 (Dynamic Decisions in
Maintenance). One expected result is the development of prototype PDA-based mobile maintenance agent devices,
which should operate within the e-maintenance architecture (with sensors, smart tags, CMMS, maintenance expert,
ERP, MES) in order to bring mobile maintenance management closer to the daily practice at the shop floor.
Experimentations will be carried out on Fiat and Volvo production sites in order to assess the impact of the e-
maintenance architecture and mobile maintenance agent devices on maintenance management.

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