1. 1st CREMA / C2NET Industrial Workshop
Cloud-based Rapid Elastic MAnufacturing
Machinery
Maintenance
Aizea Lojo
Juan López de Armentia
Xabier De Carlos
Mikel Anasagasti
Jon Rodriguez
1st CREMA / C2NET Industrial Workshop

2. Fagor Arrasate founder member of the Mondragon Corporation
world leader in the design and manufacture of mechanical and hydraulic presses, complete stamping systems, transfer presses and many other machines
metal forming manufacturer with the world’s largest product portfolio.

3. IK4-Ikerlan Industry 4.0 projects
Electronics, Information and Communication Technologies
Specialists in embedded HW/SW.
Strongly committed to industrial dependability and industrial cyber security.
30 engineers with certification in dependable system’s development.
Private research centre not-for-profit, oriented to public service
Leader in transferring technology to industry
Member of the IK4 Research Alliance
Energy and Power Electronics
Focussing on developing energy-efficient solutions.
Advanced Manufacturing
Product design, reliability and associated services.
Development of control, monitoring and smart maintenance solutions.
Industry 4.0
projects

4. Goizper
one of the leading technology suppliers in power transmission components: brakes, clutches, turning systems, gear boxes, cams, elevators, etc.
manufactures and supplies customized power transmission components to meet market needs in sectors like metal forming, automotive, aeronautics, packaging, construction, marine, machine tools, etc.
focused on the design, manufacture and marketing of manual sprayers and dusters for treatments in farming, gardening, industry, construction, cleaning, pest control and vector control.

5. ON MACHINERY MAINTENANCE HOW CREMA SOLVES THESE PROBLEMS
In this presentation
EXISTING PROBLEMS
ON MACHINERY MAINTENANCE
HOW CREMA SOLVES THESE PROBLEMS

6. ON MACHINERY MAINTENANCE HOW CREMA SOLVES THESE PROBLEMS
In this presentation
EXISTING PROBLEMS
ON MACHINERY MAINTENANCE !
CONTEXT
EXISTING
PROBLEMS
POSSIBLE
SOLUTIONS
HOW CREMA SOLVES THESE PROBLEMS

7. Machinery Maintenance!
EXISTING
PROBLEMS
POSSIBLE
SOLUTIONS
CONTEXT

8. Machinery Maintenance: Context
Mechanic Press machine:
A machine that accumulates energy by means of a flywheel and transmits it through a Clutch Brake and a Crankshaft to a die.
Clutch brake:
A Clutch Brake is a mechanical device that engages and disengages the power transmission, especially from driving to driven shaft. Clutches are used whenever the transmission of power or motion must be controlled.

9. Machinery Maintenance: Context
Clutch brake break  Press Machine Stopped
Press machine stopped
TAS team travel
Analyse clutch brake
Order supply
Installation & Setup
Press Machine DOWNTIME
operators stopped, customer parts deliveries in risk, …

10. Machinery Maintenance: Context
Fagor and Goizper TAS teams urgently travel to the customer’s plant
Press machine stopped
TAS team travel
Analyse clutch brake
Order supply
TAS team travel
Installation & Setup
Problems and delays:
Visa, special tools, weather, spare parts delivery issues, …

11. Machinery Maintenance: Context
Analisis of the clutch brake at the customers plant
Press machine stopped
TAS team travel
Analyse clutch brake
Order supply
TAS team travel
Installation & Setup
Sometimes TAS teams can fix the problem, but others not …

12. Machinery Maintenance: Context
New clutch brake required:
order manufacturing to the supplier.
designed specifically for each press machine
usually there is not stock for this part
Press machine stopped
TAS team travel
Analyse clutch brake
Order supply
TAS team travel
Installation & Setup
Time required  Press machine downtime increase

13. Machinery Maintenance: Context
TAS teams travel to the customer’s plant and the new clutch brake is delivered
Press machine stopped
TAS team travel
Analyse clutch brake
Order supply
TAS team travel
Installation & Setup

14. Machinery Maintenance: Context
When TAS teams and supply are at the customers plant, clutch brake installation and set up is performed.
Press machine stopped
TAS team travel
Analyse clutch brake
Order supply
TAS team travel
Installation & Setup

15. Machinery Maintenance!
EXISTING
PROBLEMS
POSSIBLE
SOLUTIONS
CONTEXT

16. Machinery Maintenance: Problems
Now
The machinery monitoring and maintenance is reactive and manual.
Data is not collected continuously.
The customer directly reports the errors.
Specialized teams connect remotely to perform teleservice.
Cybersecurity problems.
High Costs!!
lack of clutch brake data monitoring
lack of a fast and reliable spare parts management
1. High costs for all the chain (Press machine user, Press manufacturer, Clutch Brake manufacturer) due to:
2.Neccesity of downtime decrease because of a Clutch Brake failure
Downtime losses!
Need to minimize downtime when a clutch break failure occurs.

17. Machinery Maintenance!
EXISTING
PROBLEMS
POSSIBLE
SOLUTIONS
CONTEXT

18. Machinery Maintenance: Solution
Now
The machinery monitoring and maintenance is reactive and manual.
Data is not collected continuously.
The customer directly reports the errors.
Specialized teams connect remotely to perform teleservice.
Cybersecurity problems.
Ideally
Automatic monitoring of the machine with local persistence.
Send data continuously to the cloud.
Anticipate to the machine errors defining some KPI’s and Alarms.
Availability of these data through some kind of application.
More secure solutions through CREMA platform.
1. High costs for all the chain (Press machine user, Press manufacturer, Clutch Brake manufacturer) due to:
2.Neccesity of downtime decrease because of a Clutch Brake failure

19. ON MACHINERY MAINTENANCE HOW CREMA SOLVES THESE PROBLEMS
In this presentation
EXISTING PROBLEMS
ON MACHINERY MAINTENANCE
HOW CREMA SOLVES THESE PROBLEMS

20. ON MACHINERY MAINTENANCE HOW CREMA SOLVES THESE PROBLEMS
In this presentation
EXISTING PROBLEMS
ON MACHINERY MAINTENANCE
HOW CREMA SOLVES THESE PROBLEMS

21. How CREMA will solve problems
Define machine maintenance process and execute.
Cloud Collaborative
Process Design Time Environment
Cloud Process and Messaging Runtime Environment

22. How CREMA solves problems
INGEST
PERSIST
MONITOR
MAINTENANCE PLAN
DATA ANALYTICS
COLLECT
TRANSPORT

23. How CREMA solves problems
COLLECT
MONITOR
MAINTENANCE PLAN
DATA ANALYTICS
PERSIST
INGEST
TRANSPORT

24. How CREMA will solve problems
Collect data from press machine & clutch brake sensors
Clutch Brake

25. How CREMA will solve problems
Collect data of each stroke from press machine & clutch brake sensors
LOCAL
DATA FILE
persist
bus
sensor signals

26. How CREMA will solve problems
Collect data from press machine & clutch brake sensors
LOCAL DATA
FILE
Unifies data coming from press machine PLC and clutch brake sensors.
Data is persisted in a local file into an Industrial PC.

27. How CREMA will solve problems
Collect data from press machine & clutch brake sensors
each stroke ≈
3-4 s

28. How CREMA solves problems
COLLECT
MONITOR
MAINTENANCE PLAN
DATA ANALYTICS
PERSIST
INGEST
TRANSPORT

29. How CREMA solves problems
Get data from datalogger and transport to CREMA.
LOCAL DATA
FILE
SEND TO
CREMA

30. How CREMA solves problems
COLLECT
MONITOR
MAINTENANCE PLAN
DATA ANALYTICS
PERSIST
INGEST
TRANSPORT

31. How CREMA solves problems
Ingests data from the press machine and clutch brake, and processes it
Data
Harmonization
Services
Transform data into CREMA format
Message Bus

32. How CREMA solves problems
COLLECT
MONITOR
MAINTENANCE PLAN
DATA ANALYTICS
PERSIST
INGEST
TRANSPORT

33. How CREMA solves problems
Monitor ingested press machine & clutch brake data.
Customer is able to define business rules & thresholds.
Monitoring
and Alerting

34. How CREMA solves problems
Monitor ingested press machine & clutch brake data.
Data is monitored and alarms are triggered based on the previously defined business rules & thresholds.
Data collected per millisecond per day many alarm triggered.
Per alarm save the starting date and hour and the end time date and time.
For not annoying the operator, trigger alarm if it is triggered more than 15 times in one day.
Have a list with the alarm historic entering from w.
Monitoring
and Alerting

35. How CREMA solves problems
COLLECT
MONITOR
MAINTENANCE PLAN
DATA ANALYTICS
PERSIST
INGEST
TRANSPORT

36. How CREMA solves problems
CREMA provides mechanisms to analyze press machine & clutch brake data
Press machine & clutch brake data
Big Data
Analytics

37. How CREMA solves problems
COLLECT
MONITOR
MAINTENANCE PLAN
DATA ANALYTICS
PERSIST
INGEST
TRANSPORT

38. How CREMA solves problems
CREMA automatically plans maintenance based on alarms (monitor) and analysed data.
Decrease machine downtime and maintenance cost.
TAS Teams
Design Time
& Runtime
Optimisation
Optimized maintenance
planning
Suppliers
Requirements

39. How CREMA solves problems
COLLECT
MONITOR
MAINTENANCE PLAN
DATA ANALYTICS
PERSIST
INGEST
TRANSPORT

40. How CREMA solves problems
Persist data ingested by CREMA into a database.
Press machine & clutch brake data
Cloud-based RAID
Infraestructure

41. MACHINERY MAINTENANCE: BENEFITS FROM CREMA

42. Machinery Maintenance: CREMA Benefits
INGEST
PERSIST
MONITOR
MAINTENANCE PLAN
DATA ANALYTICS
COLLECT
TRANSPORT
CREMA provides:
Automatic monitoring of the press machine.
Ingest data from the press machine providing mechanisms for data analysis and monitor.
Preventive maintenance: Anticipate to the machine errors and automatically schedule maintenance.
CREMA provides mechanisms to
minimize the production downtimes
of the press machine and its components.
Automatic monitoring of the press machine with local persistence.
Send data continuously to the cloud.
Anticipate to the machine errors defining some KPI’s and Alarms.
Availability of these data through some kind of application.

43. Machinery Maintenance: CREMA Benefits
INGEST
PERSIST
MONITOR
MAINTENANCE PLAN
DATA ANALYTICS
COLLECT
TRANSPORT
↓DOWNTIME =
↑ CUSTOMER PRODUCTIVITY
↓TAS & SUPPLIER COST
CREMA provides mechanisms to
minimize the production downtimes
of the press machine and its components.
Automatic monitoring of the press machine with local persistence.
Send data continuously to the cloud.
Anticipate to the machine errors defining some KPI’s and Alarms.
Availability of these data through some kind of application.

44. Machinery Maintenance: CREMA Benefits
Expected impact of applying CREMA on machinery maintenance:
↓ time of
machine downtime
↓unscheduled
machine downtimes
Up to 60% reduction of unscheduled machine downtimes on customers due to a better tracking of critical machine components performance.
15% reduction of machine downtime on customers because of the increased visibility of machines behaviour in customers by means of a better management of expected future needs.
Up to 50% reduction of intervention time on customers because GOIZ can manufacture in advance critical components sub-assemblies to simplify substitution operations on customers.
25% reduction of intervention costs by a better coordination between customers, spare parts suppliers (GOIZ) and TAS companies avoiding additional costs and time due to a non-presence of spare parts on the client or non-scheduled machine downtime to perform the intervention
↓ intervention time
↓ intervention costs

46. Machinery Maintenance CREMA Cloud-based Rapid Elastic MAnufacturing|
1st CREMA / C2NET Industrial Workshop