Decision Support Systems,

Condition Monitoring &

KPIs for Remanufacturing
Ian Graham
Product Remanufacturing Service System

Vision
3
An Interconnected Remanufacturing Ecosystem
Using information from the Complete Product Lifecycle
Product Remanufacturing Decision Support
PREMANUS Project
$7.7m over 46 months
10 partners including SKF, CRF (FIAT) & SAP
LU lead 2 work packages & 3 deliverables (> 100 PMs & $1m)
PREMANUS at Loughborough University
o Service Requirements for Remanufacturing (WP1 72 PMs)
o Dissemination and Exploitation (WP7 41 PMs)
Framework of current remanufacturing, servicing and end-of life practices
KPI definition for remanufacturing (performance management)
Business Decision Support System (algorithm development)
Process optimisation
Activity Based Costing, modeling and simulation
Fuzzy Statistical Case Based Reasoning
Deployed as webservices
Consortium
Loughborough University
Loughborough University
A top 15 UK university (top 5 for engineering)
105 years of research-led innovation
16,000 students, 3,000 staff
UKs largest campus (440 acres)
10 academic schools
New Olympic Park London campus in 2015
Wolfson School of Mechanical and Manufacturing Engineering
Wolfson School of Mechanical and Manufacturing Engineering
One of the largest UK Engineering Schools
(1200 students, 165 staff)
95% of research rated as world leading or
international standing
$17m research funding PA
Two national IMRCs ( $80m)
Todays presentation
Supply Chain Integration
Condition Monitoring *
Dealer Networks
Decision Support Systems
Resource forecasting *
Core classification
Performance Measurement
Production KPIs
Eco KPIs
Remanufacturing KPIs *
Todays presentation
Supply Chain Integration
Condition Monitoring *
Dealer Networks
Decision Support Systems
Resource forecasting *
Core classification
Performance Measurement *
Production KPIs
Eco KPIs
Remanufacturing KPIs *
Architecture
PREMANUS Gateways
Regulate services and information
within the PREMANUS system
PREMANUS Clients
Gather information, services and
resources for the BDSS apps
PREMANUS Cloud
Provides services to the
PREMANUS Clients and Gateways
Condition Monitoring
Supply Chain Integration
Using Middle-of-Life (MoL) product data
Condition monitoring
Remote inspection
Maintenance and servicing
Data logging (telematics)
Dealer networks


Condition Monitoring
Sensors located at specific
points on the gearbox indicate
critical reman components
Condition Monitoring
Archived or live data from the life of
the asset used to predict condition
Condition Monitoring
Condition Monitoring
Resource forecasting
Resource forecasting algorithms
ABC Monte Carlo simulation
Mainly used in:
high-volume
low variability
linear production
data rich
Fuzzy-stat CBR
Mainly used in:
high-value
low-volume
high variability
data poor
This is not a *USER* interface
Its just for development & demo!
LU Cost Prediction Web Service will be
deployed M2M in October 2014
Cost Forecasting Webservice
Link to gearbox cost forcasting webservice
Cost Forecasting Webservice
Link to gearbox cost forcasting webservice
Performance Measurement
Standard KPIs
Eco KPIs
Reman KPIs
General Production KPIs for Remanufacturing
Production
KPIs
WIP
OEE
LT / CT
HPU
PM
QA
nC
RR
PS
Work In Progress
General Production KPIs for Remanufacturing
Overall Equipment Effectiveness
Lead Time / Cycle Time
Hours Per (equivalent) Unit
Product Margin
Quotation Accuracy
Number of Concessions
Rejection Rate
Personnel Saturation
General Production KPIs for Remanufacturing
Eco-KPIs
Eco-
KPIs
Material used
Recycled
material used
Energy
consumption
Direct energy
consumption
Indirect
energy
consumption
Water
withdrawal
Total
greenhouse
gas emissions
Total waste
by weight
Eco-KPIs
Material
Energy
Water
Emissions
Waste
Eco-KPIs
Remanufacturing KPIs
Reman
KPIs
CPR
NCC
OCCA
DCC CVPR
SRc
SRp
CDR
Remanufacturing KPIs
Core / Product Ratio
New Component Costs (and Source)
Overall Core Class Accuracy
Distribution of Core Classes
Core Value / Core Price Ratio
Component Salvage Rate
Product Salvage Rate
Core Disposal Rate
Remanufacturing KPIs
Balanced Scorecard
Balanced
Scorecard
Production
KPIs
Eco-KPIs
Reman
KPIs
34
Benefits
Workload smoothing
Better core procurement
Accurate process planning
Accurate resource prediction
Reduce unnecessary disassembly
Lead-time & cycle-time reduction
Predictive component ordering
Value
Reduce:




Leverage in-house knowledge & data
Improve customer response
Risk
Cost
Time
Waste
Eco impact
Thank-you questions please
i.j.graham@lboro.ac.uk

www.premanus.eu