Mateusz Baran – 10007

Raden Mailisa Fitria - 10011

Vincent August Harahap - 10014

Thematic Description 1 - Industry 4.0

There have been three industrial revolutions registered so far. First one began when mechanical
production facilities with help of water and steam power were introduced to the industry in 18th
century. Second revolution began in 1870s when labor division and mass production with new
technologies were developed. The third industrial revolution began in 1970s when transistor and
other electronic components were invented, along with IT system which resulted in automated
production lines. Currently, in 21st century, people thinking that we are not so far to the next industrial
evolution, so called industry 4.0, or it might be happening these days.

Industry 4.0 which also known as “smart industry” or “intelligent industry” is indicated by change the
production process from centralized control system to decentralized. Each machine may know his own
history and target state. Every machine is able to actively monitoring and controlling the physical
world autonomously by itself. Control system may independently exchanging and responding to
information to manage industrial production processes by using analytical data. Smart industry also
means industry may control the production at all times, which will start the machine only whenever
needed based on status of the production. Industry that context-aware, assists people and machines
in execution of their tasks, while technical assistant is still required for strategic decision-maker and
flexible problem solver. To achieve this type of industry and to understand how this is possible, we
should take closer look to several main aspects of Industry 4.0

Cyber Physical System (CPS) marry physical machine and computer system. The creation of CPS
indicated in three phases which are identification technology such as RFID tags, assembly of sensors
and actuators, and becoming network compatible. By equipping every production device with sensors,
we are not only gain effective production, but also maintenance as well. The computer controls the
machine and in return gets sensor data or status feedback. With the feedback, we may predict
remaining lifetime of a machine. We can develop maintenance strategy that calculate the need for
maintenance before a breakdown by measuring the significant change interpreted as a sign of a
developing fault. It means, instead of preventive maintenance, we are able to do predictive
maintenance.

Internet of Things (IoT), where even the smallest components in the system are connected to the
internet. Every single device is embedded with its own IP address, so that we are able to collect much
more data. Stored the data, then analyzed to optimize the production and establish better
maintenance plans by understanding real time conditions of each component during production. IoT
enable sending and receiving messages over the internet which mean machines, devices, sensors and
people are communicating each other. The entire supply chain is accessible and controllable through
the internet.

Internet of Service (IoS) means system should be able to go online, can be access and easily used by
other systems. This concept is enabling services vendor to offer their service via internet. The IoS
consists of participants, an infrastructure for services, business models and the services itself. Services
are offered in structure and combined into value-added services by various suppliers; they are
communicating to users as well as consumers. Such services can support both functional and technical
features.

By integration of CPS, IoT and IoS in the operation, it will build up a smart industry. The industry which
will assist people and machine in the execution of their task based on the information gathered from
CPS and virtual world (IoT and IoS). Using Internet portals (IoS), the factory will be able to
communicate with costumer to configure and determine a personalized product. In this way, industry
will experience huge significant impact. The production become more flexible, we may have precise
production planning and balance in supply-demand. Production will no longer limited to one
condition, but also optimized according to global network of adaptive and self-organizing production
where unit belongs to more than one operator. In addition, predictive maintenance also contributes
significant impact to the industry. This maintenance strategy will reduce downtime, minimize resource
consumption and avoid unnecessary maintenance which lead to cost savings.

As you can see, the internet plays a huge part in Industry 4.0. But there are also some risks related to
having all information connected to the internet. Cyber-attacks are a regular thing. Big companies, as
well as small ones, are exposed to this kind of attack every day. Now, given that in industry 4.0, even
more components will be connected to the internet, along with all collected data about the company
and personal data, the risk of cyber-attack rises. Every company that will be the part of industrial
evolution needs to invest in new much more secure solutions.

Currently, several front liner companies have been implementing the industry 4.0. Siemens have
developed a small production line, where independent machines make different products on demand.
Bosch Software Innovations have developed so-called Industry 4.0 Innovation Cycle that is supposed
to guide through the implementation and new business models. Kuka, Dassault and Siemens provide
collaborative robots or telemaintenance systems. SAP provide supporting structures and services like
market reader of enterprise application software, cloud computing, data storage and processing.
Volkswagen and BASF have developed technologies like rapid prototyping or energy smart-building to
optimize the production.

Implementing Industry 4.0 in established factory can be daunting. On-going factory need to invest
huge amount of money to shift its regular operation to something that seems uncertain. But then you
will realize that your factory needs to be modernized, by adopting the idea of industry 4.0, this change
may leap your factory into new era. On the other hand, new factory shall implement industry 4.0.
Those new factories will have flexible production which make them much more competitive, adaptive
to the market and customer oriented. The only way to sustain is to be part of the industry evolution –
industry 4.0 – otherwise your factory will be left behind.

Reference

 P. Schjølberg, "NFV", “Industri 4.0 and Maintenance”, 2016

 M. Hernabb, T. Pentek and B. Otto , "Design Principles for Industrie 4.0 Scenarios: A Literature
Review," Working Paper, 2015.
 P. Buxmann, T. Hess and R. Ruggaber,”Internet of Services”, 2009 –
 “[Industrie 4.0 Smart Manufacturing for Future” [Online]. Available :
https://www.gtai.de/GTAI/Content/EN/Invest/_SharedDocs/Downloads/GTAI/Broch
ures/Industries/industrie4.0-smart-manufacturing-for-the-future-en.pdf
 “Industrie 4.0 - The Fourth Industrial Revolution” on Youtube:
https://www.youtube.com/watch?v=HPRURtORnis
Mateusz Baran – 10007

Raden Mailisa Fitria - 10011

Vincent August Harahap - 10014

Thematic Description 2 – Importance of Maintenance

Competition in different industries rises every year. Companies are forced to keep the pace with their
old and new rivals, to get as many costumers as possible. Customers are pickier about the products
they buy, the number of factors they look at before the purchase is higher. Design, price, reliability,
functionality and maintainability are some of the product’s aspect that costumers focus on. At
manufacturing plants, companies shall find new approaches in their production management to make
these products profitable.

Automation is one of the means to improve operational performance, by reducing human factor
mistake, increase production, etc. The higher the automation means higher in maintenance
requirement. Maintenance is combination of all technical and administrative actions, including
supervision actions, intended to retain an item in, or restore to, a state in which it can perform a
required function. The research of maintenance strategy and operations lies on two major technical
aspects: maximizing availability (Patra, 2007) and minimizing cost (Salonen and Deleryd, 2011).

The strong relationship between maintenance and production is firmly visible within a manufacturing
plant in order to keep manufacturing assets working to their expected performance. As interrelated
functions, maintenance team and production team work collaboratively to achieve the organization
aim. The implementation of best practice maintenance can improve performance, competitiveness
and market share.

Existence of maintenance function is important to increase reliability, prevent failure or take

countermeasures to minimize failure impact on equipment, manufacturing processes, quality,
environment and hence the business performance. Generally, maintenance policies are consisting of
corrective maintenance (CM) and preventive maintenance (PM). In the past, most of maintenance
activities involved corrective maintenance, and it was very costly. It is estimated that a corrective
maintenance is at least four times as expensive as preventive. This estimate does not only include the
costs of maintenance on machines and equipment, but also production losses. However, recently new
maintenance method has been introduced, it called Predictive Maintenance. Predictive maintenance
(PdM) is intended to avoid potential failure through threshold indicators and monitoring (e.g.
vibration, temperature and sound). Once the threshold is achieved, the signal is sent to the
maintenance control system to indicate that deterioration is in progress. Predictive maintenance is
expected to reduce both CM & PM interventions which leads to extension of component life, reduce
failure rate and reduce downtime due to repair (affecting MTBF and MTTF respectively) (Canito,
Fernandes et al. 2017).

From environment point of view, good maintenance will reduce energy consumptions due to
automatically turning off machines during idle time (Canito, Fernandes et al. 2017). The number of
energy, water and oil consumption will be more efficient. On the other hand, machine waste also can
be reduced. By fulfilling their role as an environmental friendly company, company may gain benefit
from their good reputation which will increase their competitiveness in the market as well.
From business performance point of view, bad maintenance will lead longer downtime (e.g. waiting
time for spare part, waiting time for right personnel to do reparation job, time to repair unit),
consequently it will increase the cost of maintenance e.g. cost of lost production and quality aspect,
cost of lost opportunities, extra capacity costs, refurbishment and upgrading costs (Wilson 2002). In
this case we can compare maintenance of manufacturing equipment to personal health care (Steve
Krar). If preventive maintenance is scheduled and done correctly, just like a person takes good care of
his body, risk of failure or sickness is reduced or even eliminated in case of predictive maintenance.
The maintenance has, in general, been considered as a cost- and not profit center. But by reducing
production losses and increasing production effectiveness, company always will have a profit out of it
(Al-Najjar 2007).

Maintenance activities are identified critical both to operator safety and to systems safety and
reliability (Grusenmeyer 2014). Maintenance activities can prevent critical failures that can lead to
minor or big accidents. There must always be failure-safe systems that can prevent accidents on a big
scale, but even those can fail. A good example of it is Deep Horizon accident. Preventive maintenance
is vital to preventing such horrible accidents. But often operators performing maintenance are
exposed to risk as well, and accidents can occur during execution of maintenance activities
(Grusenmeyer 2014). Hence the maintenance shall be performed correctly based on the procedure
such as Job Safety Analysis, Maintenance Check List.

Good way to measure company’s production effectiveness is Overall Equipment Effectiveness (OEE).
We can find out the value of OEE by multiplying Availability, Capacity Index, and Quality Index (Garg
and Deshmukh 2006). Maintenance plays huge role in every factor of this equation. If there are many
breakdowns during scheduled production time and corrective maintenance have to be carried out,
availability will sink drastically. On the other hand, if preventive maintenance is carried out as planned
during planned production breaks, there should be less probability of failures in the system and
availability will be high. Good quality of preventive maintenance can also make an impact on quality
of products and reduced number of produced items that needs to be scrapped (Al-Najjar 2007). OEE
is a very standard tool which being use by every big companies in the world.

Maintenance is very critical to production therefore most of world class companies focus on it. One of
Oil and Gas Company that leading in the maintenance field is Royal Dutch Shell. Shell is installing
thermal-imaging cameras that enable maintenance personnel to check 100 objects in the same time.
Additionally, Shell also has installed Internet of Things (IoT) sensors over its 80 oil wells in the western
African nation. The sensors enable them to remotely monitor the output and performance of each
individual well. This indicating that Shell is considering to use Predictive Maintenance Strategy.
Predictive Maintenance is one of the leading use cases for the Industrial Internet of Things and
Industry 4.0. Some of the leading companies in the world in Predictive Maintenance in industry are
Siemens, Bosh or Cisco. According to IoT-Analytics website companies like IBM and SAP have even
higher score in PdM, even though they are in different type of industry. Maintenance plays very big
role in all kinds of industries, if the company wants to be successful.

Reference

 Steve Krar. “The IMPORTANCE of MAINTENANCE”

https://www.automationmag.com/images/stories/LWTech-
files/94%20Intelligent%20Systems.pdf
 IoT-Analytics; “The Top 20 Companies Enabling Predictive Maintenance” https://iot-
analytics.com/top-20-companies-enabling-predictive-maintenance/
 Royal Dutch Shell; http://www.shell.com/energy-and-innovation/overcoming-
technologychallenges/digitalinnovation/_jcr_content/par/tabbedcontent/tab_1796261787/
textimage.stream/1473669969489/9
859ab54780896a47646a80835b00eb460996f08ea4271594219419b2f5b035f/robotics-
sensing-andprocess-control-capabilities.pdf
 Al-Najjar, B. (2007). "The lack of maintenance and not maintenance which costs: A model to
describe and quantify the impact of vibration-based maintenance on company's business."
International Journal of Production Economics 107(1): 260-273.
 Canito, A., et al. (2017). An architecture for proactive maintenance in the machinery industry.
8th International Symposium on Ambient Intelligence, ISAmI 2017. J. F. De Paz, G. Villarrubia,
G. Marreiros, V. Julian and P. Novais, Springer Verlag. 615: 254-262.
 Garg, A. and S. G. Deshmukh (2006). "Maintenance management: Literature review and
directions." Journal of Quality in Maintenance Engineering 12(3): 205-238.
 Wilson, A. (2002). Asset maintenance management : a guide to developing strategy &
improving performance. New York, Industrial Press.
Mateusz Baran – 10007

Raden Mailisa Fitria - 10011

Vincent August Harahap - 10014

Thematic Description 3 – Maintenance and Safety

Three major accidents caused by maintenance in:

1. An oil and gas plant: Piper Alpha

Piper Alpha disaster happened 6th of July, 1988, and is still considered as the most tragic disaster in oil
and gas industry. That day, out of 236 people working on that platform, 167 died. This accident
changed the oil industry forever, and is used as a reminder of worst case scenario of what could go
wrong on oil and gas platform in the sea.

Maintenance plays a huge role in safety on oil and gas platforms. Analysis of some major accidents
shows, that maintenance activities cause them. Piper Alpha disaster started with insufficient
preventive maintenance of a pressure valve, combined with a very bad communication resulted in
many deaths.

The gas that was retrieved from Piper Alpha was not just methane, which is a very light hydro-carbon
gas. It also contained propane and pentane, which are heavy hydro-carbon gasses. The heavy gases
were transformed into liquid by applying high pressure and low temperature. To keep these gases in
liquid form required powerful pressurizers, called condensate pumps.

Accident began with a routine maintenance on one of the valves on condensate pumps. Maintenance
operators removed the valve, but it was not isolated. Due to the lack of communication with another
maintenance group, the same valve was used as a replacement for a different valve that failed (Okoh
and Haugen 2013). At this point, after the lane was started, the leakage of gas occurred, and all the
remaining things that was needed for a disaster, was source of ignition. Unfortunately, sparks
occurred, and the disaster began. The ignition led to burning of crude oil, and some explosions.

The emergency exits, were very badly planned. Crude oil burns with a very thick, black smoke, which
made it impossible to take off with emergency helicopter. The combination of smoke, and night, made
it very difficult for workers to evacuate. Workers had to find a rope, and drop down to 4 C water, and
survive [1].

2. A petrochemical plant: The Phillips 66 Disaster

Event:

The Phillips 66 Houston Chemical Complex (HCC) is located at Pasadena, Texas. The plant was
producing 750,000 ton high-density polyethylene per year. On October 23, 1989, an explosion and fire
was occurred due to flammable gas release from one of the reactors. This tragic explosion and fire
resulted in the deaths of 23 employees and the destruction of nearly $750 million in property. Debris
from this explosion was found about six miles from the plant. Structural beams were twisted like
pretzels from the heat of such an intense fire, and two polyethylene production plants covering about
16 acres were destroyed(Sanders 2015).

Hazardous Material:

Highly flammable ethylene gas and isobutene as the raw material of polyethylene.

Work Process Influence:

The polyethylene reactor was undergoing a regular maintenance procedure for the removal of a
solidified polyethylene blockage on three of the six reactor settling legs. Between the polyethylene
reactor and settling, there is a DEMCO Block Valve. During Maintenance, the DEMCO Block Valve is
closed to isolate hydrocarbon from the reactor. At that time, maintenance crew had partially
disassembled the leg and managed to extract a polyethylene “log” from one section of the leg.
However, maintenance crew was connecting the air supply hoses for DEMCO valve wrongly. Their
connected the air hose for open valve in the closing valve section, and vice versa. It is leading to valve
opening when it is required to close.

Accident Process Influence

Active Failure

 Human error during maintenance that causing release of flammable hydrocarbon leading to
fire and explosion.
 Consolidated isolation via double-block valve or blind flange was not stipulated in existing
maintenance procedure

Latent Failure

 The DEMCO valve actuator mechanism did not have its lockout device in place even though
the valve capable of being physically locked in the open as well as in the closed position(James
J. Newton 2013).
 The hoses that supplied air to the valve actuator mechanism could be refurbished at any time.
There should be a produce to connect the air supply to valve and prohibition to refurbish the
hose during normal maintenance (not during the valve maintenance)
 The valve was not designed as fail-safe
 Inadequate lockout/tagout procedures for equipment in hazardous areas.
 No permanent combustible gas detection and alarm system.
 The firewater valve is not located in safe location, it shall be buried on the ground or fire
proofed.

3. The railway industry: Utkal Express Accident

In 19 August 2017, a major railway accident happened. It was known as Utkal Express accident. The
accident took place in Uttar Pradesh, India. At least 24 people have died and 156 people reported
injured. “unofficial maintenance” is being blamed for the accident. Based on investigation, some
unfinished maintenance work was found. Workers just left their workplace without any inspection nor
close the work properly. It seems the maintenance workers did not put any speed restriction signal or
proper signal warning indicating that some maintenance work was going on. It means, they either was
not followed maintenance manual, or not carried out inspection as per standards, or they did not put
speed restriction in place. As conclusion, they were not following maintenance procedures.
Basically, when we do maintenance work there are several procedures that need to be followed. The
procedure will make sure that we are doing the maintenance in place and safely. Maintenance need
to be planned in advance, with operational check lists and clear standard operation procedures [2]. In
fact, there are still worker who neglect the necessity of procedures.

If we are looking to 5S principles, one of them is standardize. Here, standardize not only mean to have
a good standard, but also to enforce and make sure that the standards are being followed by everyone.
Socialization, training and visual inspection are essential to achieve the standardize point. Later, after
standardize become systematic, it will change the culture of the organization.

Currently, a lot of study is held to prevent major railway accident. These studies mainly focus on
conducting an integrated R & D program for improvement of the railway safety, of which the target is
to reduce the accident fatalities. The main area to be improve to preventing major railway accidents
are safety system engineering and program management, the establishment of a safety management
system, and the development of techniques for assessment and accident prevention(Cho, Kwak et al.
2007).

Reference:

[1] https://www.youtube.com/watch?v=tPA_6oEgc1s

[2] http://www.firstpost.com/india/utkal-express-derailment-accident-highlights-fractures-in-
railways-hiring-procedures-skill-management-3963809.html

Cho, Y. O., et al. (2007). "An integrated R & D program for the railway safety improvement in
Korea." International Journal of Performability Engineering 3(1): 19-24.

James J. Newton, P. E., BCEE, Chair (2013). EMERGENCY PLANNING, RESPONSE, AND
RECOVERY. Alexandria, USA, Water Environment Federation.

Okoh, P. and S. Haugen (2013). The influence of maintenance on some selected major
accidents, Italian Association of Chemical Engineering - AIDIC.

Sanders, R. E. (2015). Chemical Process Safety - Learning from Case Histories (4th Edition),
Elsevier.
Mateusz Baran – 10007

Raden Mailisa Fitria - 10011

Vincent August Harahap - 10014

Thematic Description 4 – Condition Monitoring

In the industry, it is very important to observe state of the equipment in order to prevent equipment
failure and reduce the corrective maintenance cost. Optimization of maintenance cost is essential for
the company. There are several activity to observe the condition of the equipment such as Condition
Monitoring, Predictive Maintenance (PdM) and Prognostic and Health Management (PHM).

Based on EN 13306, Condition Monitoring is activity, performed either manually or automatically,

intended to measure at predetermined intervals the characteristics and parameters of the actual state
of an item. Predictive Maintenance is a strategy for determining exactly when maintenance is needed,
by attach sensors to the right places in the equipment and hence we can log and analyze condition
data, make a suitable model and then predict malfunction. Prognostics and health management
(PHM) technologies reduce time and costs for maintenance of products or processes through efficient
and cost-effective diagnostic and prognostic activities. These activities aim to provide actionable
information to enable intelligent decision-making for improved performance, safety, reliability, and
maintainability.

By performing Condition Monitoring, PdM and PHM, we can detect Potential Failure prior to
Functional Failure and hence we can maximize the useful life of equipment by allowing operation until
a functional failure is detected. Potential failure is the onset of failure defined by a failure mode. Thi
failure will be definable and detectable degradation characteristic. The potential failure can be
determined by performing several testing to the equipment. The following test normally used to the
potential failure, they are structure borne and ultra sound, vibration, oil analysis, infrared, audible
noise, or contact heat.

If all the potential failure were ignored, it may lead to functional failure. Functional failure is defined
as the inability of an asset to fulfil one or more intended function(s) to a standard of performance that
is acceptable to the user of the asset. Functional failures may include a complete failure to perform a
function. Functional Failure (FF) is normally identified and documented during FMECA (Failure Mode,
Effects and Criticality Analysis). It is critical to define Functional before valid P-F interval can be
established.

After defining the Potential Failure and Functional Failure, P-F interval curve will be created. P-F
Interval is the time between occurrence of potential and functional failure. Most failures don't take
the same amount of time to fail after the symptom is detected, so the P-F interval is expressed as an
average amount of time or cycles. The objective of P-F interval is for designing the right maintenance
task to prevent functional failures. The P-F interval can be determined by the following: laboratory
testing, analytical methods, evaluation of in-service data, engineering judgement based on inputs
from operators and maintainer, knowledge of the item’s design and of applications consisting of
similar components.

Generally, the P-F interval curve will be used to determine inspection interval. A general example
would be to set the task interval for inspection at half of the P-F interval or as minimum inspection
must occur at least once during P-F interval. The mean time between failure (MTBF) related to the
failure is not important when designing the maintenance task because it gives no reference to time of
a symptom to the failure.