PROGnostics based reliability analysis for maintenance scheduling

Cloud-based solutions for RUL evaluation and production/maintenance management

Collect and exploit data relevant to equipment condition from any source available at factory level

Validate PROGRAMS TOOLS on the AURRENAK use case (machine tool maintenance)


The main objectives of this project are to develop a model-based prognostics method integrating the FMECA and PRM approaches for the smart prediction of equipment condition, a novel MDSS tool for smart industries maintenance strategy determination and resource management integrating ERP support, and the introduction of an MSP tool to share information between involved personnel. The proposers’ approach is able to improve overall business effectiveness with respect to the following perspectives:

Increasing Availability and then Overall Equipment Effectiveness through increasing of MTBF, and reduction of MTTR and MDT.

Continuously monitoring the criticality of system components by performing/updating the FMECA analysis at first implementation or whenever a variation in the system design or composition occurs.

Building physical-based models of the components which have a higher criticality level or which status is difficult to monitor.

Determining an optimal strategy for the maintenance activities.

Creating a new schedule for the production activities that will optimize the overall system performance through a Smart Scheduling tool ensuring collaboration among the MDSS, the ERP and the RUL Estimation tool.

Providing, in addition to traditional data acquisition and management functions in a machine condition monitoring system, robust and customizable data analysis services by a cloud-based platform.

An Intra Factory Information Service will be developed to allow the company staff to be quickly informed of changes in the machine tool performances and to easily react to eventual production and maintenance activities rescheduling.

The production and maintenance schedule of complete production lines and entire plants will run with real-time flexibility in order to perform at the required level of efficiency, optimize resources and plan repair interventions.


PROGRAMS Project: AURRENAK pilot case

PROGRAMS Project: AURRENAK pilot case

Aurrenak company was founded in 1974 in Vitoria-Gasteiz (Spain) and is dedicated to the manufacture of moulds for the foundry sector (mainly for engine parts such as blocks, cylinder heads, gearboxes). Aurrenak business is oriented toward an international market....

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Thanks to PROGRAMS BPT, CALPAK (one of the @programsEU end-users) is now able to automatically retrieve the quality of the welding process and continuously monitor the Remaining Useful Life of robot's components.

Open data collected from PROGRAMS end-users pilot lines, Aurrenak and Calpak, is available on the Zenodo repository. Just look for PROGRAMS project data!

On July 2020 the deployment of PROGRAMS adaptive control solution on Aurrenak pilot line was completed: CNC parameters are now tuned based on components condition.

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Project leader: IK4-IDEKO

Project leader: FIDIA

Start/end date: October 2016 - September 2019

Start/end date: October 2017 – September 2020

Grant agreement no. 723853

Grant agreement no. 767287