When it comes to maintenance operations, many manufacturers are often swimming against the tide in their quest to lower costs and cut the time taken to perform essential tasks. We caught up with Jonathan Beaumel from JPB Système, which recently announced a technology solution designed to improve efficiencies for manufacturers.
Q: Why is it often difficult for manufacturers to achieve efficiency goals when it comes to maintenance operations?
A: It depends on the individual company and type of maintenance checks required. However, the fact that so many maintenance operations are still planned and performed manually, often by experienced operators performing sometimes basic yet time-consuming tasks, will always be counter-productive to improving efficiencies.
One laborious yet highly important task is the need for maintenance engineers to manually check the torque level of every single bolt that might be in place within a particular piece of machinery, engine, or countless other structures or vehicles.
This has led to the emergence of certain solutions that are designed to eradicate the high level of time demanded in such instances.
Q: What types of solutions are you talking about?
A: Examples include those that use ultra-sonic waves to perform inspections. However, despite enabling accurate measurements, this method has certain fundamental limitations. Most notably, such devices need physical access to the bolt, as the device needs to be plugged in on top of it. Ultra-sonic solutions also require information such as the length of the bolt, which might not be known or readily to hand.
Q: What is JPB Système doing to overcome this?
A: From our own perspective, our ‘home ground’ of aerospace is one of the foremost vertical sectors in which maintenance, repair and operations (MRO) processes require efficient, as well as standardized, safe practices. So, as a go-to supplier and solutions provider solving key challenges for manufacturers within this space – as well as other industries, – we began looking at ways to address this issue a couple of years ago. It was apparent that maintenance engineers needed something that would address the fundamental challenges within the processes, while also overcoming the shortcomings of existing solutions.
This has seen us develop a disruptive proof-of-concept solution called Smart Washer, a next generation sealing technology that enables touchless and wireless measurement of bolt axial load.
Q: Sounds interesting. Can you tell us what this is and how it works?
A: Our Smart Washer device performs the principal role of a standard washer but uses intelligent connectivity to provide maintenance and service engineers with a clear picture of axial loads. This has been achieved by incorporating a proprietary strain gauge, as well as a transmission system into the washer, which via an accompanying reading device (Smart Reader), relays the information to maintenance engineers.
Crucially, instead of having to manually verify the torque level of every single traditional bolt, maintenance engineers are notified via Smart Reader about those specific fasteners that are either too tight or too loose so they can attend to them accordingly in just a few seconds. This offers an added safety benefit as the device can reduce the eventuality of breakages in bolts caused by repeated over tightening during manual checks.
Q: Is this already in use anywhere among your customers?
A: Yes, we currently have it in beta testing across several customer sites, one of which is Airbus Helicopters, which, through ongoing trials, has reported quantifiable efficiency gains across helicopter engine maintenance.
Can you explain how they are trialling it and the results they are witnessing?
A: Helicopters can require a periodic check that necessitates removal of its engines and interior trim even before maintenance engineers can gain access and check the bolts. Once checked, the engine needs to then be re-installed and a ground-run undertaken to ensure correct installation of the engines. This is a very labour-intensive process heavy maintenance operation that would typically take around two days and require two engineers to check about 12 bolts. Through its testing of Smart Washer, Airbus Helicopters has reported that they can perform the same task in about two hours and with one engineer.
Q: Very impressive. Beyond aerospace – presumably there are other sectors where it could play an important role?
A: Absolutely; Smart Washer could potentially address several other sectors that demand extremely high safety standards and efficient maintenance processes.
For example, we see opportunities in the energy and renewable resources markets. One such application scenario is with wind engine turbines for power generation. Here, companies could leverage the device’s benefits in conjunction with a drone, saving time (and ultimately costs) as well as overcoming safety issues inherent with hard-to-access wind turbine blades. Other examples include chair lifts and cable cars at ski resorts, or high-level rides at amusement parks.
Q: What about predictive maintenance – is it possible to alert users in the applications you mention to issues before they arise?
A: Yes, it is. The amount and level of data provided by Smart Washer – that can be accessed, analyzed and processed – could in due course enable accurate live monitoring and offer the opportunity to enjoy predictive maintenance. Parameters that could be registered include tension, date, location, temperature, to name a few.
This means that whether it’s an engine for an aircraft manufacturer, wind turbine, or amusement park ride, those companies could be alerted if there is a requirement to perform maintenance – be it for a sudden and immediate issue or just according to schedule.
