Safety 4.0

In recent years augmented reality has begun to be a presence in various industrial sectors. In augmented reality the operator's perception of reality is enriched through virtual information useful to help him in his working activity. Augmented reality can be generated through various technical solutions. A first classification can be made based on how the equipment is used: head mounted displays, handheld displays, and spatial displays. Maintenance can benefit from the introduction of augmented reality as it can help operators in activities characterized by variability and in the risky activities. This is because augmented reality allows to remember the steps of the procedures and highlight the dangers if present. However, the use of augmented reality devices can bring new dangers including ergonomic problems or visual fatigue or information overload. This chapter presents an index methodology for assessing the risks introduced by augmented reality devices.

Tacit Knowledge Sharing for System Integration

Sharing of tacit knowledge is a key topic of research within the knowledge management community. Considering its embodied nature, organizations have always struggled with embedding it into their processes. Proper execution of complex processes such as system integration asks for an adequate sharing of tacit knowledge. Acknowledging the importance of lessons learned for system integration and their presence in tacit and explicit form, a case study was conducted within the Netherlands Railways. It was determined that non-sensitivity to the tacit dimension of lessons learned has resulted in their lack of utilization. Consequently, LEAF framework was developed, where LEAF stands for learnability, embraceability, applicability, and findability. The framework suggests that addressing these four features collectively can eventually lead to an adequate knowledge-sharing strategy for lessons learned. Lastly, the chapter presents an example from the Netherlands Railways to emphasize the key role technological solutions of Industry 4.0 can play in facilitating tacit knowledge sharing.

Supporting Maintenance and Mandatory Inspections Through Digital Technologies on Lifting Equipment

In this chapter, the authors present a critical analysis about the current maintenance and inspection process carried out on hazardous lifting equipment. In Italy, a mandatory audit schema is working requesting a periodic interaction between owners of the lifting equipment and inspectors. The current condition has been analyzed aiming to evaluate potential points of criticalities. A smart platform integrating physical devices—based on internet of things technologies, mobile, and cloud applications—has been developed in order to provide companies and inspectors with a reliable and modular tool to organize, certify, and trace maintenance activities developed on the specific equipment. The final purpose is to guarantee a high level of safety for this type of hazardous equipment.

Role of Additive Manufacturing in Industry 4.0 for Maintenance Engineering

The chapter describes the role of additive manufacturing (AM) in Industry 4.0 (I4.0) for maintenance engineering. A brief introduction of the fourth industrial revolution and related technologies has been included. The different AM processes with significant contributions in the relevant industry sectors have been discussed along with suitable examples. Difference between the manufacturing capabilities of conventional and AM technologies has also been presented. Owing to its high degree of design freedom, AM helps to reduce the spare parts inventory cost, component assembly cost, and can replace the discontinued parts easily. A case study presenting these key distinctive features of AM, which make it an indispensable technology for I4.0, are also discussed. Furthermore, the barriers to the adoption of AM technology by manufacturers and possible remedial actions are also discussed in brief. The knowledge gaps in terms of materials and design tools for AM have been identified and a probable road ahead has been discussed.

Applying the Fuzzy Inference Model in Maintenance Centered to Safety

The main idea of this chapter is to promote maintenance centered to safety, in accordance to adaptive fuzzy inference model, which has online adjustment to working conditions. Input data for this model are quality of service indicators of analyzed engineering system: reliability, maintainability, failure consequence, and severity and detectability. Indicators in final form are obtained with permanent monitoring of the engineering system and statistical processing. Level of safety is established by composition and ranking of indicators according to fuzzy inference engine. The problem of monitoring and processing of indicators comprising safety is solved by using the features that Industry4.0 provides. Maintenance centered to safety is important for complex, multi-hierarchy engineering systems. Sudden failures on such systems could have significant financial and environmental effect. Developed model will be tested in the final part of the chapter, in the case study of bucket wheel excavator.

Monetised Risk Values and Cost-Benefit Evaluation of Maintenance Options for Aging Equipment

In this chapter, the authors present an overview of methods that can be used to evaluate risks and opportunities for deferred maintenance interventions on aging equipment, and underline the importance to include monetised risk considerations and timeline considerations, to evaluate different scenarios connected with the possible options. Asset managers are compelled to continue operating aging assets while deferring maintenance and investment due to the constant pressure to reduce maintenance costs as well as short-term budget constraints in a changing market environment. Monetised risk values offer the opportunity to support risk-based decision-making using the data collected from the field. The chapter presents examples of two different methods and their practical applicability in two case studies in the energy sector for a company managing power stations. The use of the existing and the new proposed solutions are discussed on the basis of their applicability to the concrete examples.

Augmented Technology for Safety and Maintenance in Industry 4.0

The traditional manufacturing system is going through a rapid transformation and has brought a revolution in the industries. Industry 4.0 is considered to be a new era of the industrial revolution in which all the processes are integrated with a product to achieve higher efficiency. Digitization and automation have changed the nature of work resulting in an intelligent manufacturing system. The benefits of Industry 4.0 include higher productivity and increased flexibility. However, the implementation of the new processes and methods comes along with a lot of challenges. Industry 4.0. requires more skilled workers to handle the operations of the digitalized manufacturing system. The fourth industrial revolution or Industry 4.0 has become the absolute reality and will undoubtedly have an impact on safety and maintenance. Hence, to tackle the issues arising due to digitization is an area of concern and has to be dealt with using the innovative technologies in the manufacturing industries.

Operator 4.0 Within the Framework of Industry 4.0

Operator 4.0 is a smart and skilled operator who augments the symbiosis between intelligent machines and operators. Better integration of Operator 4.0 in Industry 4.0 can bring emphasis on human-centric approach, allowing for a paradigm shift towards a human-automation cooperation for inspiring the compulsion of human-in-the-loop. This further enhances the domain knowledge for the improvement of human cyber-physical systems for new generation automated systems. This cooperation of humans and automation makes stability in socio-technical systems with smart automation and human-machine interfacing technologies. This chapter discusses the design principles of Industry 4.0 and Operator 4.0 human-cyber physical systems.

Cybersecurity Issues and Challenges in Industry 4.0

The convergence of information technology (IT) and operational technology (OT) and the associated paradigm shift toward fourth industrial revolution (aka Industry 4.0) in companies has brought tremendous changes in technology vision with innovative technologies such as robotics, big data, cloud computing, online monitoring, internet of things (IoT), cyber-physical systems (CPS), cognitive computing, and artificial intelligence (AI). However, this transition towards the fourth industrial revolution has many benefits in productivity, efficiency, revenues, customer experience, and profitability, but also imposes many challenges. One of the challenges is to manage and secure large amount of data generated from internet of things (IoT) devices that provide many entry points for hackers in the form of a threat to exploit new and existing vulnerabilities within the network. This chapter investigates various cybersecurity issues and challenges in Industry 4.0 with more focus on three industrial case studies.

Evolution of Maintenance Processes in Industry 4.0

Several industries are looking for smart methods to increase their production throughput and operational efficiency at the lowest cost, reduced risk, and reduced spending of resources considering demands from stakeholders, governments, and competitors. To achieve this, industries are looking for possible solutions to the above problems by adopting emerging technologies. A foremost concept that is setting the pace and direction for many sectors and services is Industry 4.0. The focus is on augmenting machines and infrastructure with wireless connectivity, sensors, and intelligent systems to monitor, visualize, and communicate incidences between different entities for decision making. An aspect of physical asset management that has been enormously influenced by the new industrial set-up is the maintenance process. This chapter highlights the issues and challenges of Industry 4.0 from maintenance process viewpoint according to EN 60300-3-14. Further, a conceptual model on how maintenance process can be integrated into Industrial 4.0 architecture is proposed to enhance its value.