PPU231 – Production and product service systems

7,5 Credits

Course in Master Programme:

• Production Engineering
• Product Development

 

 

Examiner Torbjörn Ylipää E-mail: torbjorn.ylipaa@chalmers.se Telephone: +46 (0)31 – 772 27 05 Mobile: +46 (0)72 – 187 91 26

Course assistant PhD student Adriana Ito E-mail: adriana.ito@chalmers.se Mobile: +46 (0)70 – 824 01 37

 

 

1.    Purpose and aim of the course

In today’s society, there is a clear trend towards servitization. New services, business models, and strategies for bringing added value to products are emerging. Cars and aerospace engines are leased, and more companies are selling services rather than physical products. This development has increased the pressure on manufacturing companies to ensure that their products can be easily maintained and upgradeable in order to fulfill their functions over an extended life span. In particular, this development is driven by the fact that when a service is sold, the company is assuming responsibility for the product and its associated risks. To remain profitable after a shift from selling products to services, companies are forced to improve their risk management and develop Product Service Systems where potential risks are managed in all life-cycle stages.

Manufacturing companies must also ensure competitiveness by achieving high production system performance.  In fact, to be able to fulfill high and rapidly changing customer demands, today’s production systems need to be highly flexible and efficient. Maintenance organizations play a central role in achieving high production performance, and the role of maintenance is increasing in line with the development towards more complex and automated production. Therefore, maintenance organizations must assume a larger responsibility beyond the traditional confines of fixing machines when they are broken or preventing them from becoming broken again. To adopt this new role, maintenance organizations in manufacturing companies must Production Service Systems where potential risks are managed in all life cycle stages. In fact, maintenance is a particularly high-risk activity in industry, where maintenance workers are exposed to a large variety of safety risks on a daily basis.

Therefore, this course aims at providing an in-depth understanding of Production and Product Service Systems. In particular, it focuses on designing, developing and evaluating production systems or products from a servitization perspective, and understanding its implications on the manufacturing industry. Further, the course aims to provide an understanding of how Production and Product Service Systems can add value to production systems or products throughout the whole life-cycle.

Maintenance is a central part of Production and Product Service systems, and this course therefore aims at providing theoretical and practical knowledge about both prevailing and future maintenance concepts. Further, a prerequisite for realizing Production and Product Service Systems is a thorough understanding of risk and safety. This course aims to provide such an understanding from a life-cycle perspective, which includes risk and safety concepts and practical use of engineering tools to achieve economical, ecological, and social sustainability.

E-bike Inc.

This course revolves around E-bike Inc., which is a manufacturer and provider of electric bikes for city environments (E-bikes). The market for high-end E-bikes is growing rapidly and the company must adapt to these changes in order to remain competitive in the future. Throughout the entire course, the students will gain the theoretical and practical knowledge necessary to transform the company from the current state to a desired future state. This includes developing Product Service System solutions for the E-bike product line as well as improving the production system performance in order to satisfy requirements on increased production volume and production rate.

An extended description of the E-bike Inc. case will be made available during the course in the specific projects.

 

2.    Learning objectives

After the course, the students should be able to:

• LO1: Describe and apply risk and safety concepts and use engineering tools to analyze, evaluate, and reduce risks;
• LO2: Explain, implement and distinguish various prevailing maintenance concepts;
• LO3: Recognize and evaluate future maintenance concepts;
• LO4: Interpret, describe and evaluate Production and Product Service Systems;
• LO5: Demonstrate how existing production systems or products can be designed, developed and provided as Production or Product Service Systems;
• LO6: Differentiate, select and develop actions to improve production systems or products during the whole life-cycle.

 

3.    Course content and organization

The course covers the following topics:

• Theoretical basics of risk and safety;
• Engineering tools for analyzing, evaluating, and reducing risks;
• Prevailing and future maintenance concepts;
• Theory and practice of Production and Product Service Systems;
• Systematic approach for improving production systems or products during the whole life-cycle.

The course follows a problem-oriented pedagogy, and consists of lectures, a project, and workshops within the students’ area of interest. The learning activities are:

• Lectures: Provides theoretical foundation and support for project work;
• Project: Applying skills learned throughout the course to improve productions systems or products during the whole life-cycle;
• Workshops: Reflecting and discussing the implications of production and product solutions;
• Presentation: Be able to present and defend project results to industrial stakeholders.

 

4.    Examination

The course examination is based on two parts: knowledge test and project work. The final grade includes the students’ performance on the tasks, as follows:

• Individual knowledge test (maximum 30 points, 15 points to be approved). Approved knowledge test is necessary to pass the course and achieve a final grade;
• Graded report/presentation from project (maximum 70 points).

All points are summarized and the final grade is decided accordingly (total sum cannot surpass 100):

• 0-49     points = Fail
• 50-59   points = 3
• 60-79   points = 4
• 80-100 points = 5

Further details about each examination form are described below.

 

4.1 Knowledge test

Date: 2022.02.07, 13.15-15, Monday

The student needs to pass the test in order to be approved in the course and achieve a final grade. A minimum of 15 points is required to pass the test. The overall points from the test are included in the total grade on each student’s performance. If the student fails the knowledge test, a re-test needs to be performed in order to pass the course and achieve a final grade. The re-tests are available in the re-exam periods.

The knowledge test covers the content in the first two weeks of the course (i.e., until 2022.01.28) and related literature:

1. Risk management & Reliability
   
2. Servitization in industry, theory and service design
3. Maintenance concepts & Maintenance management

Specifically, the knowledge test will be based on the literature (see 5. Literature), lectures, and assignment that are covered from the beginning of the course up to 2022.01.28. The knowledge test will be performed online, via Canvas, and more information will be provided during the course. An example of the knowledge test is provided here.

 

4.2 Project work

The project work aims at applying the skills throughout the course to understand and implement Production and Product Service Systems. Two projects are included in the course, dependent on the students’ interest and programme area: one production-oriented and one product-oriented project.

The production-oriented project is aimed at improving the performance of E-Bike Inc.’s production system to ensure the company’s overall productivity and profitability by applying Production Service activities.

The product-oriented project is aimed at designing and evaluating a Product Service System (PSS) for the E-bike product line, covering the identification of value and functionality, formulating and evaluating alternative PSS concepts, and propose a candidate PSS solution (mix of product and service).

More information about the content of the projects will be provided during the course in the Product project module and the Production project module.

Forming of project groups

The maximum number of people allowed in each group is 5 people (at least 4 in each group is recommended). The students are allowed to form their own groups until Monday, 2022.01.31. To do so, go to the group page, and sign up for a group. NOTE: there are Product and Production groups - make sure to sign up for the right one! If you have any problem, contact the course assistant. If necessary, students can be assigned to groups by the examiner / course assistant.

A maximum of 70 points can be reached based on the project report/presentation. The grade of the project applies to all the members of the group. For this reason, it is important that the workload is fairly split and the level of ambition negotiated ahead.

Each group should define how to communicate internally using the digital solutions that better suits the group's needs.

Project workshops + workshop report

During the project, you will perform two joint workshops. More information concerning the workshops will be made available during the course. For the first joint workshop, the project group should also deliver a report. Participation in both workshops is mandatory.

WS1: First joint workshop

Date: 2022.02.10, 09.00-11.45, Thursday

Examination: Mandatory participation + workshop report (submit via Canvas)

Report deadline: 2022.02.18, 23.55, Friday (Not mandatory)

WS2: Second joint workshop

Date: 2022.02.24, 09.00-11.45, Thursday

Examination: Mandatory participation

Mandatory group activities during the project

• Upload the first joint workshop report at Canvas before 2022.02.18 at 23.55. - Not mandatory! Submit it if the group wants some feedback.
• Send the draft report to the opposing group via email and upload that at Canvas before 2022.03.03 at 23.55.
• Upload the Power-Point presentation slides at Canvas before 2022.03.09 at 23.55.
• Upload the written opposition report at Canvas before 2022.03.09 at 23.55.
• Upload the final report as a .pdf document at Canvas before 2022.03.18 at 23.55.

 

4.3 Additional individual mandatory activities during the course

There are four additional mandatory activities during the course:

• Pass on the “Maintenance and risk management assignment” (W4);
• Active participation in Workshop 1 (W6);
• Active participation in Workshop 2 (W8);
• Active participation in the project seminar/presentation (W10).

 

5. Literature

- Power-point presentations available during the course in the Lectures' module.

- Scientific papers/e-book sources; see below. Available from Chalmers library web page or the course web page at Canvas.

    Note: Literature for the project work is specified in the separate project PM.

• Paper 1. Tukker, A., Van den Berg, C., & Tischner, U. (2006), ”Product-services: a specific value proposition”, New business for old Europa: product-service development, competitiveness and sustainability, Greenleaf, Sheffield, pp. 22-34.
• Paper 2. Ylipää, T., Bokrantz, J., Skoogh, A. & Gopalakrishnan, M. (2017), “Identification of maintenance improvement potential using OEE assessment”, International Journal of Productivity and Performance Management, vol. 66, no. 1.
• Paper 3. Mobley, K. (2008), “Impact of Maintenance”, Maintenance Fundamentals, McGraw-Hill.
• Paper 4. Pintelon, L. & Parodi-Herz, A. (2008), “Maintenance: An Evolutionary Perspective”, Complex Systems Handbook, Springer, London.
• Paper 5. Bokrantz, J., Skoogh, A., Berlin, C. and Stahre, J. “Maintenance in Digitalised Manufacturing: Delphi-based scenarios for 2030”, International Journal of Production Economics, vol. 191, pp. 154-169.
• Paper 6. Isaksson, O., Larsson, T., & Öhrwall, A. (2009), “Development of product-service systems: challenges and opportunities for the manufacturing firm”, Journal of Engineering Design, vol. 20(4), pp. 329-348.
• Paper 7. Shostack, G. L. (1982). How to design a service. European journal of Marketing. Vol. 16 Issue: 1,pp.49-63
• Paper 8. Vandermerwe & Rada (1988) Servitization of Business: Adding Value by Adding Services. European Management Journal. Volume 6 No 4.
• Paper 9. Weibull Analysis. Reliability: A Practitioner’s Guide.
• Chapters from the book (see below): Harms-Ringdal, L. (2013) Guide to safety analysis for accident prevention, Springer: IRS Riskhantering.
  

5.1 Reading directions

Reading directions for lectures are to be found in the tables below (note that not all activities have reading directions).

Reading directions: lectures

Read before	Lecture	Reading
Production and Product Service Systems
Thursday, 2022.01.20	Servitization in industry	Paper 1
Thursday, 2022.01.20	Production Service Systems	Paper 2
Friday, 2022.01.21	Servitization theory and service design	Paper 7, Paper 8
Thursday, 2022.02.03	Development of Product Service Systems	Paper 6
Risk Management and Safety
Monday, 2022.01.24	Basic principles of risk and safety	Ch 3.1 (From book "Guide to safety analysis for accident prevention")
Monday, 2022.01.24	Risk Management Methodology	Ch 3.2, 3.4 (From book "Guide to safety analysis for accident prevention")
Monday, 2022.01.24	Risk Management Tools	Ch 4.3-4.4, 5.4 (overview) 10.1-10.3, 10.7 (FTA) 12.2 (FMEA), 15.5 (choosing tools) (From book "Guide to safety analysis for accident prevention")
Maintenance Management
Thursday, 2022.01.27	Maintenance fundamentals	Paper 3, Paper 9
Thursday, 2022.01.27	Maintenance concepts	Paper 4
Thursday, 2022.01.20	The future of maintenance management	Paper 5

 

Reading directions: project

Reading directions for the project work are specified in the project PMs.

 

6. Schedule PPU231 2022

Bellow you can find the schedule for lectures and supervision in this course. NOTE: there are specific lectures for production / product groups! They are marked in orange / green. All other lectures apply to all students.

W	Time	Activity		Resp.
3	Introduction week
	Monday, 2022.01.17, 13.15-15.00	Introduction to servitization and digitalization Introduction to E-bike Inc. Course plan and administration		TY, AI, OI, MP
	Monday, 2022.01.17, 15.15-16.00	Course plan and administration		AI
	Thursday, 2022.01.20, 08.00-09.45	Servitization in industry		OI
	Thursday, 2022.01.20, 10-11.45	Production service systems		TY
	Friday, 2022.01.21, 15.15-17.00	Servitization theory and service design		MP
4	Risk Management and Maintenance week
	Monday, 2022.01.24, 13.15-15.00	Risk management and safety	TY
	Monday, 2022.01.24, 15.15-17.00	Self-study time (theory)	---
	Thursday, 2022.01.24, 08.00-10.45	Maintenance concepts	TY
	Thursday, 2022.01.27, 11.00-11.45	Maintenance and risk management assignment	---
5	Guest lectures, PSS and Project work week #1
	Monday, 2022.01.31, 13.15-15.00	Sustainable circle – smart maintenance		Anders Källström
		Servitization		Magnus Kuschel
	Monday, 2022.01.31, 15.15-17.00	Project introduction		TY, AI, OI, MP
	Thursday, 2022.02.03, 08.00-09.45	Maintenance policy using RCM (Production groups only!)		TY
		Value and stakeholder assessment (Product groups only!)		OI
	Thursday, 2022.02.03, 10-11.45	Integrated product and production system development		MP
	Friday, 2022.02.04, 15.15-17.00	Project work – scheduled supervision Product groups --> Contact Massimo / Ola directly Production groups --> Supervision with Torbjörn (sign up here) Supervision with Adriana (sign up here)		TY, AI, OI, MP
6	Dugga and project work week #2
	Monday, 2022.02.07, 13.15-15.00	Knowledge test		TY
	Monday, 2022.02.07, 15.15-17.00	Project work – scheduled supervision Product groups --> Contact Massimo / Ola directly Production groups --> Supervision with Torbjörn (sign up here) Supervision with Adriana (sign up here)		TY, AI, OI, MP
	Thursday, 2022.02.10, 09.00-11.00	Joint workshop 1		TY, AI, OI, MP
	Thursday, 2022.02.10, 11.00-11.45	Report time for joint workshop 1		---
	Friday, 2022.02.11, 15.15-17.00	Project work – scheduled supervision Product groups --> Contact Massimo / Ola directly Production groups --> Supervision with Torbjörn (sign up here) Supervision with Adriana (sign up here)		TY, AI, OI, MP
7	Project work week #3
	Monday, 2022.02.14, 13.15-15.00	Service design – Guest lecture		Albin Andersson
	Monday, 2022.02.14, 15.15-17.00	Priority-based maintenance (Production groups only!)		AI
		Life cycle cost analysis (Product groups only!)		MP
	Thursday, 2022.02.17, 08.00-09.45	Project work		---
	Thursday, 2022.02.17, 10.00-11.45	Project work – scheduled supervision Product groups --> Contact Massimo / Ola directly Production groups --> Supervision with Torbjörn (sign up here) Supervision with Adriana (sign up here)		TY, AI, OI, MP
	Friday, 2022.02.18, 15.15-17.00	Project work		---
8	Project work week #4
	Monday, 2022.02.21, 13.15-15.00	Production service improvements (Production groups only!)		AI
		PSS cost benefit (Product groups only!)		MP
	Monday, 2022.02.21, 15.15-17.00	Project work		---
	Thursday, 2022.02.24, 09.00-11.00	Joint workshop 2		TY, AI, OI, MP
	Thursday, 2022.02.24, 11.00-11.45	Project work		---
	Friday, 2022.02.25, 15.15-17.00	Project work		---
9	Project work week #5
	Monday, 2022.02.28, 13.15-15.00	Project work – scheduled supervision Product groups --> Contact Massimo / Ola directly Production groups --> Supervision with Torbjörn (sign up here) Supervision with Adriana (sign up here)		TY, AI, OI, MP
	Monday, 2022.02.28, 15.15-17.00	Project work		---
	Thursday, 2022.03.03, 08.00-09.45	Project work		---
	Thursday, 2022.03.03, 10.00-11.45	Project work – scheduled supervision Product groups --> Contact Massimo / Ola directly Production groups --> Contact Adriana / Torbjörn directly		TY, AI, OI, MP
	Friday, 2022.03.04, 15.15-17.00	Project work		---
10	Project finalization
	Monday, 2022.03.07, 13.15-15.00	Project work		---
	Monday, 2022.03.07, 15.15-17.00	Project work		---
	Thursday, 2022.03.10, 10.00-11.45	Project seminar		TY, AI, OI, MP

TY – Torbjörn Ylipää, OI – Ola Isaksson, MP, Massimo Panarotto, AI – Adriana Ito

(***) There are specific dates available for supervision. The group should sign up via Google Forms for a time with the intended supervisor (the forms will be made available during the course). A Zoom link for the supervision will also be provided on the due time.

--- There are specific dates that the group is supposed to work by itself. If you have a specific question, you can contact your supervisor via email. If necessary, an additional meeting can be booked.

 

7.    Learning Objectives – Activities Matrix

The activities matrix shows the connections between course elements. Each learning objective is connected to the learning activities and assessment tasks throughout the course.

 

Learning objectives / Activity	LO1	LO2	LO3	LO4	LO5	LO6
Introduction lecture	X
Servitization in industry lecture	X	X		X
Production service systems lecture			X	X
Servitization theory and service design lecture
Risk management and safety lecture	X	X	X			X
Maintenance fundamentals lecture		X			X
Maintenance concepts lecture	X	X				X
Maintenance exercise	X	X				X
The future of maintenance management lecture			X	X
Development of product service systems lecture		X		X	X
Integrated product and production development lecture			X	X	X	X
Written knowledge test	X	X	X	X	X	X
Workshops	X	X	X	X	X	X
Project	X	X	X	X	X	X
Presentation				X	X	X