Search

In recent years, the way that maintenance is carried out has evolved due to the incorporation of digital tools and Industry 4.0 concepts. By connecting to and communicating with their production system, companies can now gather information about the current and future health of the equipment, enabling more efficient control through a process called predictive maintenance (PdM). The goal of PdM is to reduce unplanned downtimes and proactively address maintenance needs before failures occur. However, it can be challenging for industrial practitioners to implement an intelligent maintenance system that effectively manages data. This paper presents a methodology for developing and implementing a PdM system in the automotive industry, using open standards and scalable data management capabilities. The platform is validated through the presentation of two industry use cases. [ABSTRACT FROM AUTHOR]

This paper considers a multi-period multi-product capacitated lot-sizing problem. It develops an integrated predictive maintenance and production planning framework using deep learning and mathematical programming. The objective is to minimise the sum of maintenance, setup, holding, backorder, and production costs, while satisfying the demand for all products over the horizon under consideration. Based on a rolling horizon approach, the model dynamically integrates data-driven predictive maintenance and production planning. The used maintenance policy includes replacements and minimal repairs that are considered as preventive and corrective maintenance, respectively. To select preventive maintenance actions, a long short-term memory model is employed to accurately predict the health condition of the machine. Each rolling horizon consists of ordinary and forecast stages, and by collecting new sensor data, the maintenance and production decisions are simultaneously updated. The resulting integrated framework is validated using a benchmarking data set. The results are compared for different approaches to highlight the advantages of the proposed framework. [ABSTRACT FROM AUTHOR]

Predictive Maintenance (PdM) solutions assist decision-makers by predicting equipment health and scheduling maintenance actions, but their implementation in industry remains problematic. Specifically, prior research repeatedly indicates that decision-makers often refuse to adopt the data-driven, system-generated advice in their working procedures. In this paper, we address these acceptance issues by studying how PdM implementation changes the nature of decision-makers' work and how these changes affect their acceptance of PdM systems. We build on the human-centric Smith-Carayon Work System model to synthesise literature from research areas where system acceptance has been explored in more detail. Consequently, we expand the maintenance literature by investigating the human-, task-, and organisational characteristics of PdM implementation. Following the literature review, we distil ten propositions regarding decision-making behaviour in PdM settings. Next, we verify each proposition's relevance through in-depth interviews with experts from both academia and industry. Based on the propositions and interviews, we identify four factors that facilitate PdM adoption: trust between decision-maker and model (maker), control in the decision-making process, availability of sufficient cognitive resources, and proper organisational allocation of decision-making. Our results contribute to a fundamental understanding of acceptance behaviour in a PdM context and provide recommendations to increase the effectiveness of PdM implementations. [ABSTRACT FROM AUTHOR]

This article presents an innovative predictive maintenance for grinding mills, aiming to enhance operational efficiency and minimize downtime. Leveraging advancements in data analytics and IoT sensor technologies, the approach integrates vibration signal forecasting, LSTM-based fast Fourier transform (FFT) analysis, and convolutional neural networks (CNNs) to detect faults early on. The method involves creating LSTM models to forecast vibration signals based on historical data and using FFT analysis to identify fault frequencies associated with the grinding process. Additionally, techniques such as Mel-frequency cepstral coefficients (MFCCs), short-time Fourier transform (STFT), and continuous wavelet transform (CWT) are employed for spectrogram extraction, providing valuable insights into machinery conditions. Validation on real-world datasets with 99.95% of accuracy with 1 in AUC-ROC, showcases the robust predictive performance of the model and has reached 99.96% of accuracy for 16 classes with an AUC-ROC of 1 using CWRU dataset, surpassing existing approaches and demonstrating its potential for proactive maintenance across various industries beyond mining. [ABSTRACT FROM AUTHOR]

In industry, the monitoring and diagnosis of production processes are crucial issues in ensuring plant reliability, performance and quality. In particular, food processing operations, such as coffee roasting, are subject to numerous risks of failure that can impact on productivity and the quality of the final product. In this context, the main objective of this study was to develop an innovative method for the diagnosis and prognosis of failures in a coffee roasting process. The proposed method differs from standard approaches by using the particle swarm optimization (PSO) algorithm applied to the analysis of signatures of key process variables. This new approach has improved fault detection, with a recognition rate of over 90% for the main types of fault identified, such as heating problems, air obstructions or leaks. In addition to diagnostics, the method has also demonstrated its effectiveness in prognosticating the state of health of the process, with an average error on the prediction of remaining service life reduced to 15%, compared with 35% for fixed-threshold methods. This work has therefore enabled us to develop an innovative method offering superior performance to standard approaches for the diagnosis and prognosis of failures in the roasting process. [ABSTRACT FROM AUTHOR]

The study presents a comprehensive framework for integrating foundation models (FMs), federated learning (FL), and Artificial Intelligence of Things (AIoT) technologies to enhance aircraft health monitoring systems (AHMSs). The proposed architecture uses the strengths of both centralized and decentralized learning approaches, combining the broad knowledge capture of foundation models with the privacy-preserving and adaptive nature of federated learning. Through extensive simulations on a representative aircraft fleet, the integrated FM + FL approach demonstrated consistently superior performance compared to standalone implementations across multiple key metrics, including prediction accuracy, model size efficiency, and convergence speed. The framework establishes a robust digital twin ecosystem for real-time monitoring, predictive maintenance, and fleet-wide optimization. Comparative analysis reveals significant improvements in anomaly detection capabilities and reduced false alarm rates compared to traditional methods. The study conducts a systematic evaluation of the benefits and limitations of FM, FL, and integrated approaches in AHMS, examining their implications for system robustness, scalability, and security. Statistical analysis confirms that the integrated approach substantially enhances precision and recall in identifying potential failures while optimizing computational resources and training time. This paper outlines a detailed aviation ecosystem architecture integrating these advanced AI technologies across centralized processing, client, and communication domains. Future research directions are identified, focusing on improving model efficiency, ensuring generalization across diverse operational conditions, and addressing regulatory and ethical considerations. [ABSTRACT FROM AUTHOR]

The use of wireless technology in common marine engineering applications as a medium for data transaction in measurement and control systems, is not as popular as it should be. This article aims to demonstrate the advantages of using wireless technology in maritime engineering applications through a proposed Wi-Fi based wireless system dedicated to performance and safety monitoring in marine cargo cranes. The system is based on some concepts that were suggested in the earlier literature to perform authenticated data transmission from multiple sensors through using both the ESP-NOW protocol and the WebSerial remote serial monitor. The introduced system will be integrated with an already installed system in order to render the means for implementing effective principles in automation and control engineering, such as functional safety and predictive maintenance. Additionally, this article will highlight the economic efficiency of adopting wireless technology instead of cabling as a medium for data transaction in measurement and control systems in marine engineering applications such as cargo cranes. [ABSTRACT FROM AUTHOR]

Summary: With the rapid advancement of intelligent manufacturing, ensuring equipment safety has become a crucial prerequisite for enterprise production. In the engineer‐to‐order (ETO) production mode, characterized by diverse equipment types and frequent adjustments in production lines, equipment maintenance has become increasingly complex. Traditional maintenance plans are no longer adequate to meet the evolving demands of equipment maintenance. This paper proposes a security‐enhanced predictive maintenance scheme specifically designed for ETO‐type production equipment. The scheme utilizes industrial Internet of Things (IIoT) technology to monitor machines and equipment, constructs prediction models using machine learning methods, and reinforces the security of the prediction system through adoption of a decentralized architecture with blockchain distributed storage. In this experiment, six supervised learning models were compared, and it was found that the model based on the random forest algorithm achieved an outstanding accuracy rate of 98.88%. Furthermore, the average total response time for generating predictions within the system is 2.0 s, demonstrating a performance suitable for practical equipment maintenance applications. [ABSTRACT FROM AUTHOR]

Introduction: This study explores the shift toward predictive maintenance through real-time data analytics to minimize machine downtime and improve machinery insights in industrial environments. Predictive maintenance aims to enable proactive interventions by predicting failures, enhancing operational efficiency. Methods: The research was conducted in three stages. First, BA Glass equipment was sensorized using OPC Router and PowerStudio SCADA to facilitate real-time data extraction. A predictive maintenance algorithm was then developed in Python to analyze sensor data, predict failures, and trigger alarms. Finally, various forecasting models, including Linear and Polynomial Regression, Simple and Double Exponential Smoothing, ARIMA, and Prophet, were evaluated using a combination of blocked cross-validation and rolling window methodologies. The algorithm calculated performance metrics such as MSE, RMSE, and MAE for different parameter configurations and training sizes. Results: A comparative analysis between wired and wireless sensors concluded that wireless sensors, although more expensive, were more practical and interchangeable in the factory setting. The results from the evaluation of prediction models showed that the Double Exponential Smoothing (DES) model with an additive damped trend and linear models performed best for datasets with daily seasonality and gradual oscillations. For datasets with stable trends and higher frequency oscillations, ARIMA and Prophet models proved to be more accurate. Discussion: These findings suggest that the choice of sensors and prediction models can significantly impact the effectiveness of predictive maintenance systems. Wireless sensors offer long-term benefits in terms of flexibility and practicality, while the DES model and ARIMA/Prophet models are optimal depending on the dataset characteristics. This research highlights the value of real-time data analytics and predictive models in industrial environments for reducing downtime and improving decision-making. [ABSTRACT FROM AUTHOR]

Conventional fault diagnosis systems have constrained the automotive industry to damage vehicle maintenance and component longevity critically. Hence, there is a growing demand for advanced fault diagnosis technologies to mitigate the impact of these limitations on unplanned vehicular downtime caused by unanticipated vehicle breakdowns. Due to vehicles' increasingly complex and autonomous nature, there is a growing urgency to investigate novel diagnosis methodologies for improving safety, reliability, and maintainability. While Artificial Intelligence (AI) has provided a great opportunity in this area, a systematic review of the feasibility and application of AI for Vehicle Fault Diagnosis (VFD) systems is unavailable. Therefore, this review brings new insights into the potential of AI in VFD methodologies and offers a broad analysis using multiple techniques. We focus on reviewing relevant literature in the field of machine learning as well as deep learning algorithms for fault diagnosis in engines, lifting systems (suspensions and tires), gearboxes, and brakes, among other vehicular subsystems. We then delve into some examples of the use of AI in fault diagnosis and maintenance for electric vehicles and autonomous cars. The review elucidates the transformation of VFD systems that consequently increase accuracy, economization, and prediction in most vehicular sub-systems due to AI applications. Indeed, the limited performance of systems based on only one of these AI techniques is likely to be addressed by combinations: The integration shows that a single technique or method fails its expectations, which can lead to more reliable and versatile diagnostic support. By synthesizing current information and distinguishing forthcoming patterns, this work aims to accelerate advancement in smart automotive innovations, conforming with the requests of Industry 4.0 and adding to the progression of more secure, more dependable vehicles. The findings underscored the necessity for cross-disciplinary cooperation and examined the total potential of AI in vehicle default analysis. [ABSTRACT FROM AUTHOR]

Maintenance is crucial for ensuring equipment reliability and minimizing downtime while managing associated costs. This study investigates a datadriven approach to predicting machine faults using Response Surface Methodology (RSM) and Adaptive Neuro-Fuzzy Inference System (ANFIS). RSM was employed to develop a mathematical model to analyze how operational parameters such as pressure, voltage, current, vibration, and temperature affect fault occurrence. Data were collected at three levels for each parameter using a central composite design. The model identified that faults peaked at a pressure of 28.38 N/m2, an operating voltage of 431.77 V, current consumption of 12.54 A, machine vibration of 47.17 Hz, and temperature of 25°C, with a maximum of 25 faults observed. Conversely, the lowest fault detection occurred at a pressure of 29.42 N/m2, an operating voltage of 441.04 V, current consumption of 12.04 A, machine vibration of 49.46 Hz, and temperature of 46.5°C. A strong correlation was found between these parameters and machine faults, with the model achieving high accuracy (R2 = 98.22%) and statistical significance (p-value <0.05), demonstrating its reliability in predicting faults. The study also compared RSM with ANFIS for fault detection and process optimization in the beverage industry. While RSM effectively optimized parameter relationships, ANFIS, with its adaptive learning capabilities, provided superior fault prediction accuracy. This comparative analysis highlighted the strengths of both methods and suggested that integrating them could enhance predictive maintenance strategies. The findings offer valuable insights for industry practitioners, recommending a combined approach to improve fault detection, optimize production processes, and enhance operational efficiency. [ABSTRACT FROM AUTHOR]

Maritime transport has adapted to recent political and economic shifts by addressing stringent pollution reduction requirements, redrawing transport routes for safety, reducing onboard technical incidents, managing data security risks and transitioning to autonomous vessels. This paper presents a novel approach to predictive maintenance in the maritime industry, leveraging Artificial Intelligence (AI) and Machine Learning (ML) techniques to enhance fault detection and maintenance planning for naval systems. Traditional maintenance strategies, such as corrective and preventive maintenance, are increasingly ineffective in meeting the high safety and efficiency standards required by maritime operations. The proposed model integrates AI-driven methods to process operational data from shipboard systems, enabling more accurate fault diagnosis and early identification of system failures. By analyzing historical operational data, ML algorithms identify patterns and estimate the functional states, helping prevent unplanned failures and costly downtime. This approach is critical in environments where technical failures are a leading cause of incidents, as demonstrated by the high rate of machinery-related accidents in maritime operations. Our study highlights the growing importance of AI and ML in predictive maintenance and offers a practical tool for improving operational safety and efficiency in the naval industry. The paper discusses the development of a fault detection approach, evaluates its performance on real shipboard data-through tests on a seawater cooling system from an oil tanker and concludes with insights into the broader implications of AI-driven maintenance in the maritime sector. [ABSTRACT FROM AUTHOR]

Copyright of GeSec: Revista de Gestao e Secretariado is the property of Sindicato das Secretarias e Secretarios do Estado de Sao Paulo (SINSESP) and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

Contact probe is broadly used for the continuous monitoring of microelectronic components in manufacturing industries. False rejection of fine product due to defective contact probe significantly reduces the yield in production. Traditionally, defect detection for contact probes heavily depends on a valid range manually defined by engineers over the measured value of certain parameters. However, the subjective range defined according to engineer experience is prone to trigger a high rate of false alarms due to the inherent noise in the measured parameters. To address this issue, we construct a health index (HI) with the contact resistance‐directly‐related features to help monitor and assess the condition of contact probe. Based on the established HI, we develop Long Short‐Term Memory (LSTM) encoder‐decoder machine learning model to assess the condition of contact probe by forecasting the HI value in the future. Encoders from LSTM and convolutional neural network (CNN) are selected as the encoder‐decoder architecture for the sequence‐to‐sequence prediction due to their advantage in extracting the correlation of features at different scales. An explainable Artificial Intelligence (XAI) technique named Local interpretable model‐agnostic explanations (LIME) is used to quantify the contribution of each feature to the model prediction. The encoder from CNN is found to outperform the LSTM encoder in extracting the inter‐feature correlation. Finally, the predicted HI is used to signal the alarm for the maintenance action of contact probe when its value is below a predefined threshold. Comparison between the action alarm triggered by the developed HI and the actual maintenance records suggests that the proposed approach achieves at least 75% accuracy for the triggered alarm in the next 15 mins. [ABSTRACT FROM AUTHOR]

Predictive maintenance has gained importance due to industrialization. Harnessing advanced technologies like sensors and data analytics enables proactive interventions, preventing unplanned downtime, reducing costs, and enhancing workplace safety. They play a crucial role in optimizing industrial operations, ensuring the efficiency, reliability, and longevity of equipment, which have become increasingly vital in the context of industrialization. The analysis of time series' stationarity is a powerful and agnostic approach to studying variations and trends that may indicate imminent failures in equipment, thus contributing to the effectiveness of predictive maintenance in industrial environments. The present paper explores the use of the Augmented Dickey–Fuller p-value temporal variation as a possible method for determining trends in sensor time series and thus anticipating possible failures of a wood chip pump in the paper industry. [ABSTRACT FROM AUTHOR]

This paper presents a comprehensive framework for implementing digital twins in aircraft lifecycle management, with a focus on using data-driven models to enhance decision-making and operational efficiency. The proposed framework integrates cutting-edge technologies such as IoT sensors, big data analytics, machine learning, 6G communication, and cloud computing to create a robust digital twin ecosystem. This paper explores the key components of the framework, including lifecycle phases, new technologies, and models for digital twins. It discusses the challenges of creating accurate digital twins during aircraft operation and maintenance and proposes solutions using emerging technologies. The framework incorporates physics-based, data-driven, and hybrid models to simulate and predict aircraft behavior. Supporting components like data management, federated learning, and analytics tools enable seamless integration and operation. This paper also examines decision-making models, a knowledge-driven approach, limitations of current implementations, and future research directions. This holistic framework aims to transform fragmented aircraft data into comprehensive, real-time digital representations that can enhance safety, efficiency, and sustainability throughout the aircraft lifecycle. [ABSTRACT FROM AUTHOR]

The term “digital twin” is becoming increasingly prevalent in both research and politics with regard to infrastructure structures. Industry is making significant advancements in the fields of automation and autonomy. While numerous definitions are in circulation, some of which are identical, many are similar in nature. This work examines the digital twin from its original industry perspective and considers its relevance to the constructional engineering sector. The objective of this study is to provide an overview of the current approaches in the Industry 4.0 and constructional engineering industry, examining the associated technical opportunities and challenges. The study compares the definitions, requirements and projects executed in this field. The technologies under examination are contrasted on the basis of their position within the data model. The preliminary findings suggest that some solutions for Industry 4.0 have already been developed for the construction engineering sector. However, it must be acknowledged that some solutions have yet to be fully validated. [ABSTRACT FROM AUTHOR]

Smart systems such as data-driven machine health monitoring are emerging as powerful technology for advanced manufacturing as a result of the availability of low-cost sensors, wireless communication, and advances in Machine Learning (ML) and Artificial Intelligence (AI). Predictive maintenance (PdM) has become increasingly popular in manufacturing, which can identify approaching failures, determine root causes of operation anomalies, estimate the current health state of a system, and predict the future state and time when a component will fail in the absence of an intervention. One weakness of many past studies is the lack of run-to-failure data from an actual production environment. This paper presents run-to-failure data for the air compressor of an injection molding machine. A Long Short-Term Memory (LSTM) Recurrent Neural Network (RNN) is proposed to detect bearing faults in the air compressor, which can capture the long-term dependencies without losing the capability to identify local dependencies. The model achieves a 97.4% of prediction accuracy (95.3% of overall accuracy). Experiments for machine state classification are also conducted, and the classification performance compares favorably with conventional models. [ABSTRACT FROM AUTHOR]

The sustainability of enterprises in an increasingly competitive environment is proportional to their ability to use the resources efficiently. Maintenance departments are critical to ensure that resources are ready and operational. Increasing the efficiency of maintenance departments depends on reducing the number of failures, performing planned maintenance on time and sustaining availability of spare parts needed. Therefore, it is vital that businesses consider predictive maintenance and spare parts jointly. In this study, predictive maintenance and spare parts integration studies are carried out using gearbox failure data and spare parts consumption data of a bus fleet. This study aims to contribute to the reduction of failure costs by finding failure patterns and predicting the subsequent failures and spare parts to be used. The sequential pattern mining approach was used to determine failure patterns and the traditional frequent itemset mining approach was used to predict spare parts. As a result, 45 failure patterns were found. Rules with a reliability of up to 79% were obtained. In addition, spare part clusters with a support value of approximately 40% were created. With this valuable information, businesses are able to investigate root causes, take precautions against future failures, make predictions about the spare parts that will be needed, and develop joint maintenance planning and inventory management policies. [ABSTRACT FROM AUTHOR]

The advancement to Urban 4.0 requires urban digitization and predictive maintenance of infrastructure to improve efficiency, durability, and quality of life. This study aims to integrate intelligent technologies for the predictive maintenance of photovoltaic panel systems, which serve as essential smart city renewable energy sources. In addition, we employ vision transformers (ViT), a deep learning architecture devoted to evolving image analysis, to detect anomalies in PV systems. The ViT model is pre-trained on ImageNet to exploit a comprehensive set of relevant visual features from the PV images and classify the input PV panel. Furthermore, the developed system was integrated into a web application that allows users to upload PV images, automatically detect anomalies, and provide detailed panel information, such as PV panel type, defect probability, and anomaly status. A comparative study using several convolutional neural network architectures (VGG, ResNet, and AlexNet) and the ViT transformer was conducted. Therefore, the adopted ViT model performs excellently in anomaly detection, where the ViT achieves an AUC of 0.96. Finally, the proposed approach excels at the prompt identification of potential defects detection, reducing maintenance costs, advancing equipment lifetime, and optimizing PV system implementation. [ABSTRACT FROM AUTHOR]

This study develops a Convolutional Autoencoder (CAE) and deep neural network (DNN)-based model optimized for real-time signal processing and high accuracy in motor fault diagnosis. This model learns complex patterns from voltage and current data and precisely analyzes them in combination with DNN through latent space representation. Traditional diagnostic methods relied on vibration and current sensors, empirical knowledge, or harmonic and threshold-based monitoring, but they had limitations in recognizing complex patterns and providing accurate diagnoses. Our model significantly enhances the accuracy of power data analysis and fault diagnosis by mapping each phase (R, S, and T) of the electrical system to the red, green, and blue (RGB) channels of image processing and applying various signal processing techniques. Optimized for real-time data streaming, this model demonstrated high practicality and effectiveness in an actual industrial environment, achieving 99.9% accuracy, 99.8% recall, and 99.9% precision. Specifically, it was able to more accurately diagnose motor efficiency and fault risks by utilizing power system analysis indicators such as phase voltage, total harmonic distortion (THD), and voltage unbalance. This integrated approach significantly enhances the real-time applicability of electric motor fault diagnosis and is expected to provide a crucial foundation for various industrial applications in the future. [ABSTRACT FROM AUTHOR]

The advent of 6G technology will transforms aviation, particularly in the realm of aircraft health monitoring systems (AHMSs). This paper explores the transformative potential of 6G in enhancing real-time data exchange, predictive maintenance, and overall communication efficiency within the aviation sector. By using ultra-fast data transmission, low latency, and advanced AI integration, 6G enables the development of a unified AHMS architecture that significantly improves aircraft safety, operational efficiency, and reliability. The proposed eight-layer AHMS model, incorporating digital twins, federated learning, and edge computing, showcases how 6G can revolutionize aircraft maintenance by providing continuous, real-time monitoring and decision-making capabilities. [ABSTRACT FROM AUTHOR]

The increasing complexity of modern aircraft systems necessitates advanced monitoring solutions to ensure operational safety and efficiency. Traditional aircraft health monitoring systems (AHMS) often rely on reactive maintenance strategies, detecting only visible faults while leaving underlying issues unaddressed. This gap can lead to critical failures and unplanned downtime, resulting in significant operational costs. To address this issue, this paper proposes the integration of artificial intelligence (AI) and blockchain technologies within an enhanced AHMS, utilizing the iceberg model as a conceptual framework to illustrate both visible and hidden defects. The model highlights the importance of detecting and addressing issues at the earliest possible stages, ensuring that hidden defects are identified and mitigated before they evolve into significant failures. The rationale behind this approach lies in the need for a predictive maintenance system capable of identifying and mitigating hidden risks before they escalate. Key tasks completed in this study include: a comparative analysis of the proposed system with existing monitoring solutions, the selection of AI algorithms for fault prediction, and the development of a blockchain-based infrastructure for secure, transparent data sharing. The evolution of AHMS is discussed, emphasizing the shift from traditional monitoring to advanced, predictive, and prescriptive maintenance approaches. This integrated approach demonstrates the potential to significantly improve fault detection, optimize maintenance schedules, and enhance data security across the aviation industry. [ABSTRACT FROM AUTHOR]

Production efficiency is used to determine the best conditions for manufacturing goods at the lowest possible unit cost. When achieved, production efficiency leads to increased revenues for the manufacturer, enhanced employee safety, and a satisfied customer base. Production efficiency not only measures the amount of resources that are needed for production but also considers the productivity levels and the state of the production lines. In this context, online anomaly detection (AD) is an important tool for maintaining the reliability of the production ecosystem. With advancements in artificial intelligence and the growing significance of identifying and mitigating anomalies across different fields, approaches based on artificial neural networks facilitate the recognition of intricate types of anomalies by taking into account both temporal and contextual attributes. In this paper, a lightweight framework based on the Echo State Network (ESN) model running at the edge is introduced for online AD. Compared to other AD methods, such as Long Short-Term Memory (LSTM), it achieves superior precision, accuracy, and recall metrics while reducing training time, CO2 emissions, and the need for high computational resources. The preliminary evaluation of the proposed solution was conducted using a low-resource computing device at the edge of the real production machine through an Industrial Internet of Things (IIoT) smart meter module. The machine used to test the proposed solution was provided by the Italian company SIFIM Srl, which manufactures filter mats for industrial kitchens. Experimental results demonstrate the feasibility of developing an AD method that achieves high accuracy, with the ESN-based framework reaching 85 % compared to 80.88 % for the LSTM-based model. Furthermore, this method requires minimal hardware resources, with a training time of 9.5 s compared to 2.100 s for the other model. [ABSTRACT FROM AUTHOR]

Predictive maintenance (PM) is a data-driven approach to performing proactive maintenance by analyzing the condition of the equipment in any industrial setting. The high-precision sensors are widely adapted to meticulously analyze critical maintenance conditions using such a datadriven approach. In a similar context, a fiber brag grating (FBG) sensor is a passive and high-precision sensor that is widely used in industries where conventional sensors are not preferred. Broadly, this article presents four sub elements of the proposed integrated system such as the design of the sensor element, signal processing scheme (SPS), machine learning (ML) model for predicting anomalies, and decision support system (DSS) to suggest maintenance actions. Also, this article highlights an experimental case study on vibration monitoring and analysis of real-time signals for making proactive maintenance decisions. An FBG vibration sensor of center wavelength 1,550 nm is designed and utilized to acquire real-time vibration signatures of a rotating machine under test. A piezoelectric vibration sensor is used with the FBG sensor to compare the vibration response obtained during the test. Pre-processing of raw signals is performed using a moving average filter (MAV) followed by a low pass filter to nullify the effect of noise. To obtain proactive maintenance decisions, a DSS model is prepared by considering the processed vibration signatures. Various maintenance conditions are tested during the experimental analysis and detailed results analysis are presented. [ABSTRACT FROM AUTHOR]

This article proposes a comprehensive framework for enhancing information exchange in ship maintenance through the integration of Digital Twins (DTs) and the Internet of Things (IoT). The maritime industry faces significant challenges in maintaining ships due to issues like data silos, delayed information flow, and insufficient real-time updates. By leveraging advanced technologies such as DTs and IoT, this framework aims to optimize maintenance processes, improve decision-making, and increase the operational efficiency of maritime vessels. Digital Twins create virtual replicas of physical assets, allowing for continuous monitoring, simulation, and prediction of ship conditions. Meanwhile, IoT devices enable real-time data collection and transmission from various ship components, facilitating a seamless flow of information. This integrated approach enhances predictive maintenance capabilities, reduces downtime, and improves resource allocation. The article will delve into the architecture of the proposed framework, implementation steps, and potential challenges, supported by case studies that demonstrate its practical application and benefits. By addressing these aspects, the framework aims to provide a robust solution for modernizing ship maintenance operations and ensuring the longevity and reliability of maritime assets. [ABSTRACT FROM AUTHOR]

Italy offers a cultural heritage of considerable value that needs to be protected. Indeed, natural deterioration linked to the passage of time affects ancient artifacts and buildings. Sometimes, the deterioration compromises the functionality of cultural assets, pushing them toward decay. In this scenario, effective intervention seems impossible on the various critical points because of the wide variability of factors involved and the wide range of possible treatments. However, the spread of low-cost technologies has led to the possibility of having different devices and sensors able to communicate and interact with each other and humans: the Internet of Things (IoT). In this scenario, the IoT paradigm makes it possible to map reality by defining a coherent virtual representation (Digital Twin), which could help preserve Cultural Heritage. This work introduces an IoT-based system combining monitoring, predictive maintenance, and decision-making regarding the implementable interventions for protecting cultural heritage buildings. For this purpose, deep and machine learning techniques allow for the detection and classification of damages on specific materials. The experimental phase consists of two phases: the first aims to evaluate the accuracy of the proposed architecture, and the second exploits a prototype capable of interacting with expert users. The results of the experimental campaign are promising. [ABSTRACT FROM AUTHOR]

Optimizing energy consumption is an important aspect of industrial competitiveness, as it directly impacts operational efficiency, cost reduction, and sustainability goals. In this context, anomaly detection (AD) becomes a valuable methodology, as it supports maintenance activities in the manufacturing sector, allowing for early intervention to prevent energy waste and maintain optimal performance. Here, an AD-based method is proposed and studied to support energy-saving predictive maintenance of production lines using time series acquired directly from the field. This paper proposes a deep echo state network (DeepESN)-based method for anomaly detection by analyzing energy consumption data sets from production lines. Compared with traditional prediction methods, such as recurrent neural networks with long short-term memory (LSTM), although both models show similar time series trends, the DeepESN-based method studied here appears to have some advantages, such as timelier error detection and higher prediction accuracy. In addition, the DeepESN-based method has been shown to be more accurate in predicting the occurrence of failure. The proposed solution has been extensively tested in a real-world pilot case consisting of an automated metal filter production line equipped with industrial smart meters to acquire energy data during production phases; the time series, composed of 88 variables associated with energy parameters, was then processed using the techniques introduced earlier. The results show that our method enables earlier error detection and achieves higher prediction accuracy when running on an edge device. [ABSTRACT FROM AUTHOR]

This paper focuses on predictive maintenance for simple machinery systems monitored by the Internet of Things (IoT). As these systems can be challenging to model due to their complexity, diverse typologies, and limited operational lifespans, traditional predictive maintenance approaches face obstacles due to the lack of extensive historical data. To address this issue, we propose a novel clustering-based process that identifies potential machinery faults. The proposed approach lies in empowering decision-makers to define predictive maintenance policies based on the reliability of the proposed fault classification. Through a case study involving real sensor data from the doors of a transportation vehicle, specifically a bus, we demonstrate the practical applicability and effectiveness of our method in preemptively preventing faults and enhancing maintenance practices. By leveraging IoT sensor data and employing clustering techniques, our approach offers a promising avenue for cost-effective predictive maintenance strategies in simple machinery systems. As part of the quality assurance, a comparison between the predictive maintenance model for a simple machinery system, pattern recognition neural network, and support vector machine approaches has been conducted. For the last two methods, the performance is lower than the first one proposed. [ABSTRACT FROM AUTHOR]

Maintaining the condition of a vessel and its equipment guarantees the scheduled completion of voyages and the safety of the crew. This paper presents condition monitoring techniques for early detection of faults related to piston rings in remote cylinders of two-stroke marine diesel engines. Operational sensor data from the main engine of a container ship are provided by a shipping company. A graphical approach complimented by correlation heatmaps and feature importance from gradient boosting trees are used for feature selection. Support Vector Machine, Random Forest and Extreme Gradient Boosting Trees are tested for residual generation from the nominal behavior. The residual time series gives a good indication of the degradation of the system and can be used for alarm raising under strict rules. It is proven that the proposed method could alert the engine crew of a change in the condition of the piston rings much earlier than existing methods. [ABSTRACT FROM AUTHOR]

The integration of Artificial Intelligence (AI)-driven predictive maintenance (PM) into the management of medical 3D printing machines promises a revolutionary advancement in operational efficiency and reliability. Traditional maintenance approaches often fail to optimize machine uptime and reduce costs effectively. AI and Machine Learning (ML) techniques, however, enable a proactive maintenance strategy by predicting potential failures and facilitating timely interventions. This ensures continuous high-quality production, which is critical for patient safety and effective medical care. AI-driven PM employs various methods, including supervised and unsupervised learning, neural networks, and natural language processing, to analyze vast datasets and perform intelligent diagnostics. The incorporation of advanced technologies such as digital twins, generative AI, collaborative robots, blockchain, and the Industrial Internet of Things (IIoT) further enhances fault detection, transparency, and efficiency in maintenance processes. The benefits of this approach include minimized downtime, cost savings, improved safety, and increased equipment reliability. As AI technology advances, its role in PM will become more sophisticated, establishing new benchmarks for the operation and management of 3D printing machines. This proactive maintenance strategy not only improves performance but also provides a competitive advantage in the healthcare sector. [ABSTRACT FROM AUTHOR]

Predictive maintenance has gained increasing importance recently due to the potential for significant losses resulting from unexpected machine failures. Additionally, the lengthy process of manufacturing and shipping components for repairs exacerbates the situation. Therefore, this study aims to introduce a method for enhancing time series classification performance by integrating MINImally RandOm Convolutional KErnel Transform (MiniRocket) and a genetic algorithm (GA)-based ensemble method for time series classification in the context of predictive maintenance. This study lies in the utilization of MiniRocket for feature extraction from time series data, which significantly reduces computational time compared to traditional methods. Additionally, the application of GA to ensemble learning of homogenous tree-based models introduces a unique strategy for improving classification accuracy and stability. In addition to using benchmark datasets, this study addresses a real-world problem provided by a prominent wire and cable company in Taiwan. Based on experimental results involving a wire drawing machine, it is evident that employing the GA within the ensemble learning method yields superior performance compared to using individual algorithms. This improvement is consistent across both benchmark and case study datasets, in terms of four performance indicators. [ABSTRACT FROM AUTHOR]

Maritime transportation is crucial for global trade but faces significant risks and operational challenges. Ensuring safety is essential for protecting lives, the environment, and economic stability. This review explores the role of artificial intelligence (AI) in enhancing maritime safety and risk management. Key AI applications include risk analysis, crew resource management, hazardous material handling, predictive maintenance, and navigation systems. AI systems identify potential hazards, provide real-time decision support, monitor hazardous materials, predict equipment failures, and optimize shipping routes. Case studies, such as Wärtsilä's Fleet Operations Solution and ABB Ability™ Marine Pilot Vision, illustrate the benefits of AI in improving safety and efficiency. Despite these advancements, integrating AI poses challenges related to infrastructure compatibility, data quality, and regulatory issues. Addressing these is essential for successful AI implementation. This review highlights AI's potential to transform maritime safety, emphasizing the need for innovation, standardized practices, and robust regulatory frameworks to achieve safer and more efficient maritime operations. [ABSTRACT FROM AUTHOR]

This research focuses on enhancing the preventive maintenance strategies currently employed for induction motors within ship propulsion systems, advocating for a shift towards a predictive maintenance model. It introduces a real-time monitoring framework that continuously observes the induction motor, providing essential support to maintenance personnel. The motor operates under a range of environmental and operational conditions, including temperature fluctuations, rotational speeds, and mechanical loads. These variations can obscure the current time series data, potentially masking signs of actual damage and hindering effective damage detection. To tackle this issue, the proposed framework utilizes artificial intelligence (AI) technology, specifically the well-established autoencoder, in conjunction with the Mahalanobis statistical distance. This approach accounts for the diverse operating conditions during the training phase, allowing it to model complex, non-linear relationships and effectively differentiate between normal and anomalous states. The framework is integrated into a decision support platform designed for real-time operations in maritime settings, offering a sophisticated system architecture that aims to align advanced damage detection methodologies with the maritime industry's need for real-time, user-friendly solutions. [ABSTRACT FROM AUTHOR]

Copyright of Machine Tool & Hydraulics is the property of Guangzhou Mechanical Engineering Research Institute (GMERI) and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

In recent years, there has been growing interest in employing predictive methods to forecast the remaining useful life of industrial equipment. However, the challenge lies in how to take advantage of the dynamic predictive information to facilitate the maintenance of decision‐making. This problem becomes particularly challenging for complex industrial systems consisting of multiple components with economic dependencies. This paper aims at providing an effective maintenance strategy for multi‐component systems based on predictive information, while considering economic dependencies among different system components. To this end, a dynamic predictive maintenance (PdM) strategy that minimizes the mean maintenance cost over a decision period is proposed, where both long‐term and short‐term policies are integrated into the decision‐making framework. Specifically, the long‐term policy is formulated using predictions derived from historical degradation data through a Long Short‐Term Memory (LSTM) model. Concurrently, real‐time monitoring data is employed to forecast imminent degradation in components, serving as a basis for determining the necessity of short‐term adjustments. This paper embeds the consideration of economic dependencies among components within the maintenance strategy design and employs hierarchical clustering to establish an effective and efficient maintenance grouping policy. The experimental results demonstrate that our proposed strategy significantly outperforms conventional approaches, including block‐based and age‐based maintenance, resulting in substantial cost savings. The proposed strategy is also compared with a similar version without grouping, and the results verify the added value of the optimal maintenance grouping policy in cost reduction. Moreover, a comprehensive analysis of the proposed method is provided, including the impact of different inspection costs and inspection intervals on maintenance decision‐making, which can provide insightful guidance to various PdM scenarios in practice. [ABSTRACT FROM AUTHOR]

The development of artificial intelligence-based tools is having a big impact on industry. In this context, the maintenance operations of important assets and industrial resources are changing, both from a theoretical and a practical perspective. Namely, conventional maintenance reacts to faults and breakdowns as they occur or schedules the necessary inspections of systems and their parts at fixed times by using statistics on component failures, but this can be improved by a predictive maintenance based on the real component's health status, which is inspected by appropriate sensors. In this way, maintenance time and costs are saved. Improvements can be achieved even in the marine industry, in which complex ship propulsion systems are produced for operation in many different scenarios. In more detail, data-driven models, through machine learning (ML) algorithms, generate the expected values of monitored variables for comparison with real measurements on the asset, for a diagnosis based on the difference between expectations and observations. The first step towards realization of predictive maintenance is choosing the ML algorithm. This selection is often not the consequence of an in-depth analysis of the different algorithms available in the literature. For that reason, here the authors propose a framework to support an initial implementation stage of predictive maintenance based on a benchmarking of the most suitable ML algorithms. The comparison is tested to predict failures of the oil circuit in a diesel marine engine as a case study. The algorithms are compared by considering not only the mean squared error between the algorithm predictions and the data, but also the response time, which is a crucial variable for maintenance. The results clearly indicate the framework well supports predictive maintenance and the prediction error and running time are appropriate variables to choose the most suitable ML algorithm for prediction. Moreover, the proposed framework can be used to test different algorithms, on the basis of more performance indexes, and to apply predictive maintenance to other engine components. [ABSTRACT FROM AUTHOR]

This paper presents a comparative analysis of deep learning techniques for anomaly detection and failure prediction. We explore various deep learning architectures on an IoT dataset, including recurrent neural networks (RNNs, LSTMs and GRUs), convolutional neural networks (CNNs) and transformers, to assess their effectiveness in anomaly detection and failure prediction. It was found that the hybrid transformer-GRU configuration delivers the highest accuracy, albeit at the cost of requiring the longest computational time for training. Furthermore, we employ explainability techniques to elucidate the decision-making processes of these black box models and evaluate their behaviour. By analysing the inner workings of the models, we aim at providing insights into the factors influencing failure predictions. Through comprehensive experimentation and analysis on sensor data collected from a water pump, this study contributes to the understanding of deep learning methodologies for anomaly detection and failure prediction and underscores the importance of model interpretability in critical applications such as prognostics and health management. Additionally, we specify the architecture for deploying these models in a real environment using the RAI4.0 metamodel, meant for designing, configuring and automatically deploying distributed stream-based industrial applications. Our findings will offer valuable guidance for practitioners seeking to deploy deep learning techniques effectively in predictive maintenance systems, facilitating informed decision-making and enhancing reliability and efficiency in industrial operations. [ABSTRACT FROM AUTHOR]

In the chemical industry, stable reactor operation is essential for consistent production. Motor failures can disrupt operations, resulting in economic losses and safety risks. Traditional monitoring methods, based on human experience and simple current monitoring, often need to be faster and more accurate. The rapid development of artificial intelligence provides powerful tools for early fault detection and maintenance. In this study, the Hotelling T2 index is used to calculate the root mean square values of the normal motor's x, y, and z axes. A long short-term memory (LSTM) model creates a trend model for the Hotelling T2 index, determining an early warning threshold. Current anomaly detection follows the ISO 10816-1 standard, while future anomaly prediction uses the T2-LSTM trend model. Validated at a chemical plant in Southern Taiwan, the method shows 98% agreement between the predicted and actual anomalies over three months, demonstrating its effectiveness. The T2-LSTM model significantly improves the accuracy of motor fault detection, potentially reducing economic losses and improving safety in the chemical industry. Future research will focus on reducing false alarms and integrating more sensor data. [ABSTRACT FROM AUTHOR]