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The supply of customer-specific products is leading to the increasing technical complexity of machines and plants in the manufacturing process. In order to ensure the availability of the machines and plants, maintenance is considered as an essential key. The application of cyber-physical systems enables the complexity to be mastered by improving the availability of information, implementing predictive maintenance strategies and the provision of all relevant information in real-time. The present research project deals with the development of a cost-effective and retrofittable smart maintenance system for the application of ultraviolet (UV) lamps. UV lamps are used in a variety of applications such as curing of materials and water disinfection, where UV lamps are still used instead of UV LED due to their higher effectiveness. The smart maintenance system enables continuous condition monitoring of the UV lamp through the integration of sensors. The data obtained are compared with data from existing lifetime models of UV lamps to provide information about the remaining useful lifetime of the UV lamp. This ensures needs-based maintenance measures and more efficient use of UV lamps. Furthermore, it is important to have accurate information on the remaining useful lifetime of a UV lamp, as the unplanned breakdown of a UV lamp can have far-reaching consequences. The key element is the functional model of the envisioned cyber-physical system, describing the dependencies between the sensors and actuator, the condition monitoring system as well as the IoT platform. Based on the requirements developed and the functional model, the necessary hardware and software are selected. Finally, the system is developed and retrofitted to a simulated curing process of a 3D printer to validate its functional capability. The developed system leads to improved information availability of the condition of UV lamps, predictive maintenance measures and context-related provision of information.
The use of learning factories for education in maintenance concepts is limited, despite the important role maintenance plays in the effective operation of organizational assets. A training programme in a learning factory environment is presented where a combination of gamification, classroom training and learning factory applications is used to introduce students to the concepts of maintenance plan development, asset failure characteristics and the costs associated with maintenance decision-making. The programme included a practical task to develop a maintenance plan for different advanced manufacturing machines in a learning factory setting. The programme stretched over a four-day period and demonstrated how learning factories can be effectively utilized to teach management related concepts in an interdisciplinary team context, where participants had no, or very limited, previous exposure to these concepts.