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PPU231 – Production and Product Service Systems

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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

 

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 fulfil 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 of 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 fulfil high and rapidly changing customer demands, today’s production systems need to be highly flexible and efficient. Maintenance organisations 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 organisations 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 organisations 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 focusses 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 electrical 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 is available at the course website at Canvas.

 

Learning objectives

After the course, students will 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.

 

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, workshops, and a project within the students’ area of interest. The learning activities are:

  • Lectures: Provides theoretical foundation and support for project work
  • Workshops: Practical training in engineering tools
  • Project: Applying skills learned throughout the course to improve productions systems or products during the whole life-cycle
  • Presentation: Be able to present and defend project results to industrial stakeholders

 

Examination

The course examination is based on three parts: written knowledge test, workshops, and project work.

The final grade includes the students’ performance on all three assessment tasks (all tasks must be approved to pass the course):

  • Written knowledge test (maximum 25 points, 10 points to be approved). Approved knowledge test is necessary to pass the course and achieve a final grade.
  • Graded report from 3 workshops (maximum 15 points)
  • Graded report and seminar from project (maximum 60 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.

 

Written knowledge test

Date: 20200210, 13-15, Monday

The grading scale is Fail or Pass. A minimum of 10 points is required to pass the test.

The student needs to pass the test in order to be approved in the course and achieve a final grade. The overall points from the test are included in the total grade on each student’s performance. If the student fails the written 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 written knowledge test covers the content in the first three weeks of the course:

  1. Risk management
  2. Servitization
  3. Maintenance management

Specifically, the written knowledge test will be based on the literature, lectures and workshops that are covered from the introduction lecture in week 1 (200120) through the future of maintenance management lecture in week 3 (200207).

 

Workshops

During the course, you will perform three workshops (WS). More information concerning each workshop is available at the course portal Canvas.

WS1: Risk Management Tools

Start date: 200127, 13-17, Monday

Examination: Workshop report (submit via Canvas)

Deadline: 200207, 23.55, Friday

Maximum points = 5

WS2: Servitization

Start date: 200130, 08-12, Thursday

Examination: Workshop report (submit via Canvas)

Deadline: 200207, 23.55, Friday

Maximum points = 5

WS3: Reliability, maintainability, maintenance

Start date: 200206, 08-12, Thursday

Examination: Workshop report (submit via Canvas)

Deadline: 200214, 23.55, Friday

Maximum points = 5

Further specifications of the workshop are available in each workshop syllabus. Information about their examination and grading criteria are available in the document “PPU231 – Workshop reporting guide”. These are available at the course web page (Canvas). The workshops utilize three different software: Windchill Quality Solutions (WQS), JMP and Anylogic. WQS and JMP are available at the computers in PSL, but Anylogic has to be downloaded individually by each student group during workshop 2 (either to PSL computers or students’ personal computers). For further reading and instructions on WQS1, WQS2, WQS3, JMP, and Anylogic, see section “Workshops” under “Reading directions”.

Important note: To be able to access the lab without supervision you need to fill out a security form. The form is to be found at Canvas under contents.

Forming of workshop groups: Students may form their own workshop groups. Note that the workshops are team efforts and all group members must participate in the work and writing the workshop reports.

 

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).

Forming of project groups: Students may form their own workshop groups. However, one critical criterion for the production-oriented project is that each group must include at least one student with previous AutoMod experience from the MRP271 – Simulation of Production Systems course. Note that the project is a team effort and all group members must participate in the project and writing the final project report.

 

Literature

Available as an e-book at Chalmers library or the course web page at Canvas.

  • Power-point presentations available at the course homepage
  • 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.

Reading directions

Reading directions for lectures and workshops are to be found in the tables below (note that not all activities have reading directions). Chapter numbers (Ch) refer to the course textbook and paper numbers to the scientific papers listed earlier in this syllabus. In addition, all PowerPoint-materials from the lectures are also included in the course literature (necessary for both exercises and examination).

Important note: This course puts great emphasis on reading, understanding and applying the theoretical literature. Therefore, reading the literature is necessary in order to pass the course examination.


Reading directions: lectures

Date

 

Lecture

Reading

Production and Product Service Systems

Thursday, 200123, 08-10

 

Servitization in industry

Paper 1

Thursday, 200123, 10-12

 

Production Service Systems

Paper 2

Thursday, 200213, 08-10

 

Development of Product Service Systems

Paper 6

Risk Management and Safety

Friday, 200124, 15-17

 

Basic principles of risk and safety

Ch 3.1

Friday, 200124, 15-17

 

Risk Management Methodology

Ch 3.2, 3.4

Friday, 200124, 15-17

 

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)

Maintenance Management

Monday, 200203, 13-15

 

Maintenance fundamentals

Paper 3

Monday, 200203, 15-17

 

Maintenance concepts

Paper 4

Friday, 200207, 15-17

 

The future of maintenance management

Paper 5

 

Reading directions: workshops

W

Time

 

Activity

Reading

 

Workshops

4

Monday, 200127, 13-17

 

WS1: Risk Management Tools

Risk Management lecture reading directions,

WQS1 WS1:

4

Thursday, 200130, 08-12

 

WS2: Servitization

WS2: Maney (2014), Legnani et al. (2010)

5

Thursday, 200206, 08-12

 

WS3: Reliability, maintainability, maintenance

WQS1 WS3:

WQS1 – “Reliability: A Practitioners Guide” (available at Canvas)

WS1:

Reliability Block Diagrams: Chapter 2 (pp. 33-38) & Appendix B (pp. 325-328)

Additional reading (if interested):

FMEA: Chapter 6 (pp. 169-171 & 174-175)

FTA: Chapter 5 (pp. 131-146)

WS2:

The reading directions for WS2 include two practical examples of using simulation for analyzing services:

Maney, J. (2014), “Using JMP to Assess Risk in Financial Predictions by Using Monte Carlo Simulations”, JMP Discovery Summit. Presentation available on Canvas, and video presentation is available on YouTube: https://www.youtube.com/watch?v=fnT4ADhz6L0.

Legnani, E., Cavalieri, S., Marquez, A. C., & Díaz, V. G. (2010), “System Dynamics Modeling for Product-Service Systems - A case study in the agri-machine industry”. In Proc. of APMS. (available at Canvas).

WS3:

Weibull analysis: Chapter 7 (pp. 201-208)

For further instructions and support for using WQS software during workshop 1&3:

“WQS Getting Started” (available at Canvas)

FMEA: pp. 51-62

FTA: pp. 65-77

Reliability Block Diagrams: pp. 79-92

Weibull analysis: pp. 103-113

Reading directions: project

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

 

Schedule PPU231 2020

W

Time

 

Activity

Resp.

3

Introduction, Servitization, Risk Management

 

Monday, 200120, 13-15

 HC4

Introduction to Servitization and Digitalization

Introduction to E-bike Inc.

TY, JB, OI, MP

 

Monday, 200120, 15-16

 HC4

Course plan and administration

TY, JB

 

Thursday, 200123, 08-10

 HC4

Servitization in industry

OI/MP

 

Thursday, 200123, 10-12
HC4

Production Service Systems

AS

 

Friday, 200124, 15-17
HC1

Risk Management and Safety

TY

4

Risk Management and Servitization

 

Monday, 200127, 13-17

PSL

WS1: Risk Management Tools

TY, AI

 

Thursday, 200130, 08-12

PSL

WS2: Servitization

MP, JB

5

Maintenance Management

 

Monday, 200203, 13-14

HC1

Sustainable circle – smart manufacturing

Guest - Anders

 

Monday, 200203, 14-15

HC1

Sustainable circle – smart manufacturing

Guest

 

Monday, 200203, 15-17

HC1

Maintenance concepts / fundamentals

TY

 

Thursday, 200206, 08-12

PSL

WS3: Reliability, maintainability, maintenance

TY, AI

 

Friday, 200207, 15-17

HC1

The future of maintenance management

TY

Hand-ins during W5 (not later than Friday 200207 at 23.55)

  • Workshop 1 report (Risk Management Tools)
  • Workshop 2 report (Servitization)

Read “PPU231 - Workshop reporting guide” for instructions

Workshops are solved in groups during the lab sessions under the guidance of supervisors. All group members should be involved in solving the workshop problems and writing the report – the workshops are a team effort!

6

Production and Product Service Systems (Project work week #1)

 

Monday, 200210, 13-15

SB Multisal

Written knowledge test1

TY

 

Monday, 200210, 15-17

HC1

Project introduction

TY, OI, MP, AI

 

Thursday, 200213, 08-10

HB1

Development of Product Service Systems

MP

 

Thursday, 200213, 10-12

HB1

Integrated Product and Production System Development

MP

 

Friday, 200214, 15-17

PSL

Student project planning

 

Hand-ins at the end of W6 (not later than Friday 200214 at 23.55)

  • Workshop 3 report (Reliability, maintainability, maintenance)

The workshops are team efforts and all group members must participate in the work and writing the workshop reports.

7

Project work week #2

 

Schedule for project work #2 to #4 (Production and Product) are specified in separate project PMs

8

Project work week #3

 

Schedule for project work #2 to #4 (Production and Product) are specified in separate project PMs

9

Project work week #4

 

Schedule for project work #2 to #4 (Production and Product) are specified in separate project PMs

10

Project finalization

 

Monday, 200309, 13-15

EA

Joint workshop on product-production changes

AI, MP, TY

 

Monday, 200309, 15-17

PSL

Project work (last session)

AI, OI, MP

 

Thursday, 200312, 08-12

VASA3

Project seminar2

TY, AI, OI, JM, MP

Hand-ins at the end of W10 (not later than Friday 200322 at 23.55)

·       Final project report

Read “PPU231 – Project grading template” for instructions

As in the workshops, the project work is a team effort and all group members must participate in the project work and writing the final report.

 

1 Written knowledge test starts at 13:00 sharp. Room is announced in due time.

2 All students must attend the project seminar session. Both projects (production and product) will be presented during this session.

AS – Anders Skoogh, TY – Torbjörn Ylipää, JB – Jon Bokrantz, MS – Mukund Subramaniyan, OI – Ola Isaksson, MP, Massimo Panarotto, JM – Jacob Muller, AI – Adriana Ito, NM – Ninan Mathew, CL- Camilla Lundgren

 

Skärmklipp-1.PNG

Course summary:

Date Details Due