Overview

KBSI’s work with the Corpus Christi Army Depot (CCAD) has extended into the third phase of the Predictive and Preventative Expert System (PPMES) project. The focus of Phase III work is to extend the capabilities developed in the project’s first two phases and to ensure their stability within the Facilities and Equipment Maintenance System (FEMS), the maintenance management system employed by CCAD.

Approach

Phases I and II of the PPMES project demonstrated the feasibility of KBSI’s approach by establishing the effectiveness of sensor-based alerts, maintenance history data analysis for equipment failure forecasting, and maintenance data mining. Phase III will subsequently transition and harden these capabilities within CCAD by refining and implementing the maintenance data mining, statistical maintenance forecasting, and maintenance history data analysis (Equipment Remaining Life Curve Calculator) modules into FEMS. This step will involve the rigorous cleansing of FEMS data and the subsequent populating of the system with data. KBSI will work closely with CCAD’s facilities and equipment maintenance and administrative personnel to ensure that the stand-up of the FEMS system is configured properly to maximize the decision support utilities that PPMES provides.

PPMES captures live sensor data; logs and transforms analog data into digital forms using the new wavelet theory; performs diagnostic and predictive tests to project failure potential; schedules maintenance; and organizes data for reliability, availability, and maintainability analysis and the establishment of spares management policies. The system works with existing legacy systems. The data display client is designed for maximum flexibility, compatibility, and expansion using standard intranet Web browser "push" technologies.

PPMES will minimize breakdowns and defects, maximize equipment operation rates, reduce life-cycle costs, extend equipment life, improve troubleshooting, and minimize spare and replacement parts inventory. As a consequence, labor and machine productivity will increase for selected mission-critical equipment. The PPMES automates equipment usage tracking and monitors key sources of deterioration. It gathers data and provides statistical analysis capabilities that categorize, summarize, and analyze equipment status and availability. Warnings are sent to machine operators for at-risk operations.

The first two phases of the PPMES project established the effectiveness of sensor-based alerts, maintenance history data analysis for equipment failure forecasting, and maintenance data mining. The Phase III effort will subsequently transition and harden these capabilities within CCAD by refining and implementing the maintenance data mining, statistical maintenance forecasting, and maintenance history data analysis modules into FEMS. This step will involve the rigorous cleansing of FEMS data and the subsequent populating of the system with data. KBSI will work closely with CCAD's facilities and equipment maintenance and administrative personnel to ensure that the stand-up of the FEMS system is configured properly to maximize the decision support utilities that PPMES provides. In addition to implementing PPMES within FEMS, KBSI will also train CCAD personnel in the use of PPMES and FEMS. To further facilitate use of the system, KBSI will also establish and develop an intranet link for depot users of the PPMES system.

Benefits

The successful implementation of PPMES within FEMS will provide CCAD with extended capabilities for predicting and managing probable equipment failures. As a consequence, KBSI’s work with PPMES will provide the framework by which facilities and equipment maintenance at CCAD can evolve into a model and data driven enterprise.