WBSFIS-FACT
Web Based Shop Floor Information Systems – Fault
Analysis & Correlation Tool
PARD Conference 8th & 9th March 2006.
Bob Eden
Lead Engineer
© 2006 IARC
WBSFIS-FACT Project.
Agenda.
1)
Project background.
2)
Possible solutions.
3)
Project aims.
4)
Project status.
5)
Summary.
6)
Q&A.
© 2006 IARC
WBSFISWBSFIS-FACT project
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Growth of Electrical / Electronic Complexity
Electical / Electronic Content
Off-Board Communication
& Connectedness
Remote
Diagnostics
Higher Power
Requirements
ISG
In Car PC
ACC
El. Water
Infotainment
Pump
EPAS
Software
EM Valves
Telematics
PTC Heater
IVDC
ESP
PATS
Airbag
Body Elec.
ABS
Cluster
P/T Electronics
© 2006 IARC
Adaptive
Headlamps
1980
1990
Displays
E-Connectivity
X-by-Wire
Blind Spot
Networking Detection
Brake-byCAN, MOST, etc.
Wire
Adv.
Keyless
Fuel Cell
ASM Vehicle
Restraints
2000
WBSFISWBSFIS-FACT project
2010
Calendar Year
3
Warranty Costs for Electrical Failures.
Increasing
Increasing malfunctions
malfunctions and
and Warranty
Warranty Cost
Cost due
due to
to insufficient
insufficient
E/E
E/E management
management [Quality
[Quality cost
cost between
between 3-5%
3-5% of
of total
total revenue]
revenue]
Electrical/Electronic Systems
32.1%
Ignition Systems*
14.0%
Engine
11.7%
Radiator/Cooling Systems
8.2%
Wheels of Tires
7.0%
Fuel Systems
6.3%
Injection Systems
6.1%
Gears/Transmission
5.5%
Chassis*
4.0%
Other
5.1%
0%
*also Contain Electronics
10%
20%
30%
40%
Percent of Malfunctions
© 2006 IARC
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WBSFIS-FACT project.
Project Background.
¾ Increasing complexity in component and system hardware.
Automotive electrical systems have already seen rapid growth.
¾ Improve the diagnosis of complex faults.
¾ Provide better access to fault data and information.
¾ Reduce the repair times at Service centres.
© 2006 IARC
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WBSFIS-FACT Project.
Research findings.
¾ Automotive electrical problems can be complex and interactive.
¾ Parts are sometimes returned with no fault evident.
This can be costly for both the Company and the Customer.
¾ Diagnostics has not always kept pace with technology.
¾ Exchange of data and information can be slow.
Data can be stored in many locations and formats.
¾ The original source of fault data may not be accurate.
© 2006 IARC
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WBSFIS-FACT project.
Key causes of poor problem detection.
¾ Components and systems now share hardware and software.
Misdiagnosis of problems can be more frequent.
Keeping pace with new technology is challenging.
Fault detection routines may not be up to date.
¾ Time and cost pressures can cause errors in repairs.
¾ Information is not always available to support technicians.
Need good data access whilst repairs are in progress.
Data collection and analysis can be slow.
© 2006 IARC
WBSFISWBSFIS-FACT project
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WBSFIS-FACT project.
Typical fault data flow.
Component
Suppliers
Manufacturer
Service & Repair
Centres
Data base
Data base
Data base
Diagnostic
Repair unit.
Faulty
product
Fault data / information flow
Diagnostic routines and possible solutions.
© 2006 IARC
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WBSFIS-FACT project.
What’s required.
¾ Problems need to be diagnosed more effectively and correctly.
Faults need to be fixed once with no repeat failures.
¾ Technical expertise should be available at the repair centre.
The latest diagnostics tools should be available during repairs.
¾ Problems should be identified by symptom related descriptions.
Makes it easier to identify what isn’t working correctly.
¾ Fault data should be automatically collected and stored.
© 2006 IARC
WBSFISWBSFIS-FACT project
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WBSFIS-FACT project.
Project aims.
¾ Using
web based technology will provide faster access solutions.
Could have worldwide coverage using the internet.
¾ Develop
an internet based data collection and storage facility.
This would provide on line access to fault data and information.
¾ Develop
Bayesian networks to assist adaptive fault diagnostics.
Provides symptom based diagnostics to improve fault finding.
¾ Reduce
the number of returned parts which are not faulty.
This will also reduce warranty and repair costs.
© 2006 IARC
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WBSFIS-FACT project.
Project solutions.
¾ Link the symptom based diagnostics to prescribed test routines.
The most appropriate test to find the fault will be displayed.
¾ Use web based technology to access data and diagnostic systems.
Allow the diagnostic routines to be downloaded via the web.
Centrally store data for better access and manipulation.
Improve data access to allow key partners to fix faults quickly.
¾ Use adaptive learning to update the diagnostic routines.
Would automatically happen on line - no CD’s or DVD’s.
© 2006 IARC
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WBSFIS-FACT project.
Improved data flow solution.
Component
Suppliers
Manufacturer
Service & Repair
Centres
Diagnostic
Repair unit
Data / information
flow
Central database – key partners
all have access.
Web
Based
Search
engine
Additional Internet related technical data available on line.
Search and sort data facility to update diagnostic routines.
Internet based system provides easier data flow & access
© 2006 IARC
WBSFISWBSFIS-FACT project
Faulty
product
12
WBSFIS-FACT project.
System description.
¾ Problems are now described as a set of symptoms.
The closest fault symptom is selected with the appropriate tests.
The technician follows the on screen instructions.
Repairs and checks are undertaken until the fault is eliminated.
¾ At the end of the repair cycle the fault path and data are recorded.
The fault data is transmitted back to a central data base.
Problem data is stored and sorted centrally.
The fault path can be used to establish the root cause of failure.
© 2006 IARC
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WBSFIS-FACT project.
System description.
¾ This data could then be used to update the diagnostics.
Data would modify the test routine to improve fault finding.
¾ The screen display could show other data.
This could include technical bulletins and data.
Workshop manual information and circuit diagrams.
All this information could be viewed during repairs.
¾ Displaying additional web information is being investigated.
© 2006 IARC
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WBSFIS-FACT project.
System Benefits.
¾ Incorrect diagnosis of faults should reduce.
Warranty and repair costs should also be minimised.
¾ Diagnostic routines will be updated via the wireless network.
This reduces the risk of using outdated repair information.
¾ The level of data and expertise is available at all repair centres.
Pressure on hotlines and other fault support agencies will reduce.
¾ Customer satisfaction should also improve.
This should have a positive effect on Company profits and sales.
© 2006 IARC
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WBSFIS-FACT project.
Project status.
¾ The WBSFIS project is still in the research phase.
¾ Bayesian networks applied to vehicle fault finding has been
researched.
The adaptive learning using fault data is still in the research phase.
¾ A pilot study to demonstrate the principles will start in July 2006.
¾ External partners are involved in assessing the project outcomes.
Key Suppliers are engaged, Alpine,Harman Becker,UK-NSI.
¾ Project completion is December 2006.
© 2006 IARC
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WBSFIS-FACT project.
Summary.
¾ The project solutions can apply to most repair centres.
¾ The system provides improved expertise during repairs.
¾ Easier data access with quicker repairs and design
improvements.
¾ The time taken to resolve customer problems should reduce.
¾ Customer retention and satisfaction ratings should improve.
¾ Company profits should improve as repair costs reduce.
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WBSFIS-FACT project.
Q&A
© 2006 IARC
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