Machine Health and Condition Based Maintenance Mark N. Pope, General Motors.

Machine Health and Condition Based

Maintenance

Mark N. Pope, General Motors

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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

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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

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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.

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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

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

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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

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Analysis Approach: 2 Groups

Study targets: Technicians at Dealerships & OEM Service

Garages Technicians at Independent Repair Facilities

OEMs Design Suppliers Engineering Suppliers Tool Suppliers/Manufactures

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Group 1 Users

Group 2 Designers/Planners

• Gain insight from those directly involved in these systems &

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

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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

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Preliminary Results: Participant Industry


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Preliminary Results: Participant Years of Experience

%


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Preliminary Results: OEM/Supplier Group Participant Titles


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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

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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%


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“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…


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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

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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!

Machine Health and Condition Based Maintenance Mark N. Pope, General Motors.

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