machine health and condition based maintenance

Machine Health and Condition Based

Maintenance

Mark N. Pope, General Motors

2

Agenda Introduction Pre-Survey Hypothesis Purpose of Study Study Development & Timeline Analysis Approach & Study Targets Preliminary Survey Findings Next Steps Promotional Efforts & Call to Action Discussion

11AE-0209

3

IntroductionAdvancements in vehicle technology, and specifically in electrification, will have a significant impact on vehicle reliability, diagnostics & serviceability.

These technologies include: Increased number of electronic control units (ECUs) in

vehicles and equipment Hybrid Electric Vehicles (HEV)/Plug-in Electric Vehicles

(PEV)/other Electric Vehicle (EV) technologies High voltage, high current, and multiple voltage systems on

the vehicle, e.g. 48V, 300V Increased number of customer-provides (e.g. Bluetooth

devices, etc.), consumer electronics, aftermarket devices, and in vehicle infotainment devices

11AE-0209

4

Pre-Survey Hypotheses Increased complexity & new technologies could be creating a knowledge

gap that impacts service performance, warranty costs and brand image: Time-to-repair, FTF, NTF Increased repair/warranty costs Environmental implications Technician safety implications

Some Technicians may not be well equipped for current conditions: The situation will get worse because we do not have manpower, education,

skills, etc. OEMs should use more diverse tools to meet changing needs of service

technicians: The OEM/Automotive community should take advantage of the many tools

available from other industry sectors (e.g. SaaS, cloud computing, advanced information delivery models, etc.).

Members of the public may hesitate to adopt new vehicle technologies due to perceptions of low reliability/poor service.

11AE-0209

5

Purpose of Study - Objectives• Assess electrification on vehicle reliability, diagnostics and

service • Make recommendations to represent the impact of vehicle all

stakeholders: OEMs and Suppliers

Engineering, Manufacturing, Quality, Service Dealers and Service technicians,(including IRFs\aftermarket) Other industry Groups

Scan Tool designers/providers Service information authoring & delivery vendors PLM software vendors

11AE-0209

Study findings will be used to improve Education, Training, Tools & Future Design

6

Study Development & Activity Timeline

Members of SAE’s Service Technology Program Committee (STPC) and IDC Manufacturing Insights began meeting in August 2010 to discuss issues surrounding “vehicle electrification” and maintenance

Whiteboarding and initial project planning began in November 2010

First draft of survey created in December for team review and feedback

Beta testing conducted through January and February 2011; Feedback incorporated, and survey finalized.

Press release was put on the Business wire on March 7, 2011 and picked up by over 24 different websites within the first 24 hours

Survey was first published and promoted on March 10, 2011 203 Complete data submissions in 14 days, but looking for many,

many more! 11AE-0209

7

Analysis Approach: 2 GroupsStudy targets: Technicians at Dealerships & OEM Service

Garages Technicians at Independent Repair Facilities OEMs Design Suppliers Engineering Suppliers Tool Suppliers/Manufactures

11AE-0209

Group 1 Users

Group 2 Designers/Planners

• Gain insight from those directly involved in these systems &

• Identify gaps between “Users” and “Designers/Planners”

8

Preliminary Results: Participant Organization Type

Source: IDC Manufacturing Insights, 2011N=203

Of the Total Population:• 58% represent OEMs +

Suppliers• 42% represent Technicians

1) Need to bolster Technician participation

2) Specifically need to reach more Independents

9

Preliminary Results: Participant Industry


10

Preliminary Results: Participant Years of Experience

%


11

Preliminary Results: OEM/Supplier Group Participant Titles


12

Preliminary Results: TitlesDealer/Svc Garage/Independent Repair Facility Group


“Other” titles include:• Technical Communicator/Officer• Service Manager• Trainer/Instructor• Shop owner• Technical/Technology Support•Application Engineer•Manager• Service and Product Support

13

Preliminary Results: Participant Areas of Experience

Internal Combustion Powertrain

Electric/Electronic Controls (e.g. OBD, engine controls, infotainment, etc.)

Body and Chassis Systems (e.g. HVAC, steering, suspension, etc.)

Electronically Controlled Hydraulic Systems

Electric/Hybrid Powertrain

0% 20% 40% 60% 80%

72.9%

69.5%

57.6%

48.8%

38.4%


14

“How do you expect technician safety to change as a result of new vehicle technologies?”

Preliminary Results Example: OEM-Technicians Perception Gap

1= Greatly Improved

5= Much Worse

Technicians believe that their safety is in greater jeopardy with new technologies, whereas OEMs/Suppliers believe it

will be improved…Source: IDC Manufacturing Insights, 2011N=203

15

Next Steps Continue Survey Promotion Ongoing Data Analysis & Gap Identification Develop Recommendations

Present Results/Recommendations: SAE OBD Symposium, September 2011 IDC Manufacturing Insights Webcast, November Publish IDC Manufacturing Insights Report

16

Promotion Efforts & Call to ActionPromotion through multiple channels, but

participation is still lower than expected: 15,800 SAE Members, Prospects, and Affiliates 30,000 member Auto OEM Network LinkedIn

Group Identifix Member Community iATN & NADA Communities Others… STPC companies, individual efforts,

etc.CALL TO ACTION Take the survey! Promote the survey--especially with Technician

Networks (Independent participation is acutely low)

http://bit.ly/VehicleTechnologyStudy

Thank [email protected]

http://bit.ly/VehicleTechnologyStudy

Take the survey and impact the future of the automotive industry today!