Failure Pattern Recognition and Extended Tactical Spare Parts Supply Chain Planning

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The proposed extension of the project - Integrating Intelligent Maintenance Systems and Spare Parts Supply Chains - (I2MS2C) is submitted by a Brazilian-German research consortium responding to the third BRAGECRIM call. The overall project extension aims to improve the effectiveness and efficiency of spare parts supply chain (SPSC) management activities for complex technical systems by the integration of further advanced technologies in the area of Intelligent Maintenance Systems (IMS) providing information utilized by new methods from data analytics and supply chain planning in addition to the developed solutions so far. On the Brazilian side the development of a distributed IMS should improve their adaptability to change operational conditions, resulting in a better short and long term failure forecasting of a single machine and the optimized support of the service technicians during maintenance situations. The German part of the project extension is targeting at the further improvement of tactical SPSC planning results regarding costs and service level by incorporating failure patterns and condition monitoring information provided by distributed IMS and the service technicians. Furthermore, collaborative planning (CP) concepts will be analysed and adapted to the specifics of SPSC. The large condition monitoring data sets are analyzed by adapted methods from data analytics in order to detect failure patterns stemming from operational conditions. Failure forecasting methods will be developed, being able to integrate the recognized failure patterns and the condition monitoring information in order to enhance the quality of failure forecasts. These predictions serve as a foundation for the calculation of the spare parts demand based on the methods developed in the first phase of the I2MS2C project, enabling a high quality SPSC planning. In view of the tactical SPSC planning method being developed in the first project phase a higher differentiation in the considered planning domains is aspired in order to achieve a plan being more exact and feasible for the whole supply chain. For that reason, the developed integrated planning method will be extended by integrating the domains of maintenance service and production planning. Furthermore, the actors of the SPSC shall not be regarded in an isolated way, but their collaboration is an explicit research subject for achieving the intended efficiency and effectiveness gains. Therefore, existing CP concepts will be analysed regarding their applicability in tactical and operational planning across the whole SPSC and adapted accordingly, using the modelling and evaluation framework developed in the first project phase. The performance of all results will be evaluated based on a simulation of three industrial cases. A comparison between these cases will allow an investigation of the differences and similarities between German and Brazilian SPSCs.