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Integrated framework for a cost-effective and ease of Repair, Renovation and Re-use of machine tools within modern factory

Periodic Report Summary 1 - EASE-R3 (Integrated framework for a cost-effective and ease of Repair, Renovation and Re-use of machine tools within modern factory)

Project Context and Objectives:
EASE-R3 focuses on the selection of the best maintenance strategy, including decommissioning, such as renovation, repair, re-use, according to the minimization of Life Cycle Cost (LCC) and Life Cycle Assessment (LCA) related parameters. Once the selection is performed, EASE-R3 then investigates different technologies supporting maintenance tasks such as Augmented Reality (AR)-based, Virtual Reality (VR), Condition monitoring.
Current maintenance policies can be useful in answering effectiveness questions such as How can this particular machine be operated more efficiently? EASE-R3 answers to the 5 top questions of effectiveness:
How can reliability, repair and End Of Life (EOL) be included in a robust and integrated Life Cycle Cost and Life Cycle Assessment model of the factory?
PLATFORM A: Integrated Life Cycle Cost and Life Cycle Assessment platform based on Reliability & Maintainability simulations model and techniques
Which are the most cost-effective and optimal Repair strategies we should tailor for sets of components/machines of the factory?
PLATFORM B: Repair Decision Support System platform for optimal cost-effective maintenance strategy selection
Which machine and/or components should we improve and how can we reduce repair time and cost?
PLATFORM C: Seamless approach to reduce Repair time and cost of machines and components
Which are the most environmental-effective EOL strategies we should tailor for sets of components/machines of the factory?
PLATFORM D: Decommissioning Decision Support System (DDSS) platform to select optimal and environmental effective EOL strategies
How can we assess the remaining life of Re-usable components and which are most valuable Renovation technologies for the machine tools?
PLATFORM E: Enabling technologies for energy & cost effective Re-use and Renovation of machine tools.

EASE-R3 consortium is co-ordinated by FIDIA, large high speed milling machine tools builder; WIRES is a leading SME in the field of stone cutting machine tools, EKIN is a 40-years experienced SME in the field of broaching machines; CeSI is a leading SME in the framework of advanced machine tool design. Besides the machine tools manufacturers, IDEKO has a proven experience in machine tools design and machining technologies as far as milling, grinding and turning machines and processes are concerned. Laboratory of Machine Tools and Production Engineering at RWTH Aachen University, Budapest University of Technology and Economics, University of Huddersfield and Production engineering, Machine design and Automation part of the Engineering Faculty of the KU Leuven are leading universities in the field, among others, of machine tools design, simulation and machining process virtualisation and optimisation, while Politecnico di Torino participates with three departments: Control and Computer Engineering, f Environment, Land and Infrastructure Engineering and Applied Science and Technology. MACH4 is a high-tech SME with wide experience in R&M engineering, LCC modelling and designing of advanced machine tools and components. TEKS is a dynamic, multinational SME, actively involved in manufacturing and process design and optimisation of advanced materials and composite parts for the aerospace, energy and sport automotive sectors, while NEWBURGH brings to the project its large expertise in a large variety of industrial processes, and will plan to act as a potential end user to the project, emitting requirements and assessing project results. DIN is a non-profit organization recognized as a German National Standards body representing Germany in European and international standardization activities.
The EASE-R3 consortium consists of 14 European organisations coming from 7 European Countries: Germany, Italy, Spain, The United Kingdom, Belgium, France and Hungary. Participants can be grouped as follows: 7 industrial partners (6 SMEs), 1 research partner, 5 academic partners and one non-profit organisation.

Project Results:
The project is structured in 8 work packages (WPs). WP1 focuses on integrated LCC and LCA on Reliability and Maintainability (R&M) modelling, WP2 aims to develop the Repair Decision Support System platform, while WP3 to investigate Condition Monitoring approaches and Augmented Reality applications. WP4 and WP5 focus on the end-of life, hence the decommissioning decision support system and technologies for energy and cost effective reuse and renovation will be developed respectively. Remaining WPs are for demonstration sessions, dissemination, exploitation and management activities.
Methodologies developed within WP1 are available, while RDSS is under development with CBM and augmented reality applications. Other WPs, as planned, are at early stage of development. Demonstrators have been consolidated in the first part of the project, during the second part of the project the action plan will be consolidated.
Data collection was started at the beginning, but it is considered a continuous process to feed, test and validate methodologies and platforms developed. Moreover, a preliminary prototype of RDSS is available, simulations have been conducted for Condition Based Monitoring and the prototype using Augment Reality is ready.
At month 16, the Exploitation Strategy Seminar has been organized to identify and characterize the main Key Exploitable Result: Integrated framework for a cost-effective and ease of Repair, Renovation and Re-use of machine tools within modern factory.
Several dissemination activities have been conducted, mainly from universities, as expected in the first part of the project, moreover flyer and poster have been defined to support all the events.


Potential Impact:
The project will yield at least the following output:
• EASE-R3 selects the best maintenance strategy including decommissioning. Once the selection is performed, EASE-R3 investigates different technologies such as Augmented Reality (AR), Virtual reality (VR).
• It gives a software and methodology for selecting the best strategy for maintenance and end of life.
• Enables user to make an informed decision on the state of the machine regarding renew, repair and renovate
• EASE-R3 offers a solution that is better than the others as integrated framework. The technology allows to minimise costs related to maintenance as best maintenance strategy, effectiveness of use of resources. Moreover the technology adopted is not commonly used. Developed standards will secure easy integration into existing systems.
• Model-based system extended by self-learning system.
• Integrated and holistic approach (maintenance plus EOL)
• Use of innovative technologies such as Augmented Reality and Virtual Reality
• Self-contained tool (avoiding the requirement for additional software as MATLAB.
EASE-R3 proposes an integrated framework for the whole life of machine tools (from design to end of life phase). Furthermore, modules are enhanced with respect to the state of the art, as tools for maintenance and decommissioning decisions, augmented reality, etc. Standardization activities could be an adding value to the product. Users will be able to:
• renovate and reuse existing machines more cost effective than by a new one, improve maintenance activities at marketing and costs level, increase in maintainability of future design, reducing the cost of ownership, attractive to workers, people enjoy new technology like AR
• provide feasible long term maintenance
• reduce risks in management decisions
• reduce number of pieces of software
• offer a better service to customer by not having breakdowns so customer isn’t left waiting proposes an integrated framework for the whole life of machine tools (from design to end of life phase).
Project web-site is reachable at http://www.easer3.eu/ continuously updated, moreover Twitter account at https://twitter.com/ease_r3 is available for latest news, while the coordinator (Mr. Tamburini – FIDIA) is reachable at e.tamburini@fidia.it for any information.
List of Websites:
http://www.easer3.eu