This will result in improved decision-making support and greater automation with a focus on vendor-neutral approaches and plug-and-play solutions. The goal of the project is to promote advanced sensing, PHM, and control from ISA 95 manufacturing1 levels 0 (production process) through 3 (manufacturing operations management). Some proprietary solutions exist that integrate some manufacturing systems, but they apply to systems from one vendor and are often expensive and inaccessible to many manufacturers. No open standards exist that guide and manage sensing, prognostics and health management (PHM), and control at all levels (from the component to the system to the enterprise level). The simultaneous operation of complex systems within the factory increases the difficulty to determine equipment and process degradation, and resolve failures due to ill- or undefined information flow relationships. Complex system, sub-system, and component interactions within smart manufacturing systems make it challenging to determine the specific influences on process performance, especially during disruptions. There is increasing interest to leverage the same data to generate diagnostic (what happened) and prognostic (when something will happen) intelligence at the machine, process, and system levels. Early implementations of smart manufacturing technology have enabled manufacturers to use sensor-rich equipment and process the resulting data to provide decision-makers with information on many performance-related measures (e.g., machine status and utilization) and overall process health. The Prognostics, Health Management, and Control (PHMC) project will deliver methods, protocols, and tools for robust sensing, diagnostics, prognostics, and control that enable manufacturers to respond to planned and un-planned performance changes thereby enhancing the efficiency of smart manufacturing systems. The requirement for standards and guidance becomes more critical as manufacturers become capable of collecting larger volumes of data, the health of their equipment changes, and their processes evolve to meet changing consumer demand. Manufacturers need standards and guidance for how to effectively design, implement, verify, and validate monitoring, diagnostic, and prognostic technologies to enhance factory floor-level decision-making that directly impacts maintenance and control strategies. Required by DoD policy (DoD Instruction 4151.Industry Forum: Monitoring, Diagnostics, and Prognostics for Manufacturing Operations.PHM has the potential to save billions of dollars in maintenance and operation costs to the U.S.PHM can lower maintenance costs while increasing operational availability and utilization:.Given this distribution along with operational constraints and objectives for the system, maintenance activities can be scheduled to achieve the optimal cost and utilization. PHM seeks to develop sensor hardware and algorithms to detect anomalies, diagnose problems that cause the anomalies, and compute a probability distribution of time to failure. Prognostics and health management (PHM) is an advanced approach to minimize maintenance costs while maximizing operational availability and utilization of critical systems. Ideally, maintenance could be scheduled between these two extremes to minimize overall costs. However, waiting until a critical system fails is likely to lead to even higher costs because of mission interruption, added logistical difficulties, and possibly the loss of entire systems or even human life. Maintenance based on regular intervals is likely to be performed more often than needed leading to correspondingly higher costs. Maintenance of critical systems is clearly important, but it also entails significant costs in terms of parts, labor, and loss of operational availability. Failure Prediction to Optimally Balance Maintenance and Operations
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