EPSRC Centre for Innovative Manufacturing in Through-life Engineering Services

Lead Research Organisation: Cranfield University
Department Name: School of Water, Energy and Environment

Abstract

The EPSRC Centre in Coupled Whole Systems is a National Centre, hosted by Cranfield and Durham Universities. Successful high technology UK manufacturing companies are offering a range of interlinked high value products and services. High value products are typically technology intensive, expensive and reliability critical requiring engineering services (e.g. maintenance, repair and overhaul) throughout the life cycle e.g. aircraft engine, high-end cars, railway vehicle, wind turbines and defence equipment. Competitiveness is then dependent on many factors, such as design innovation for the product and added value through the services and minimisation of whole life cost. These products typically combine five major domains (structural, mechanical, electrical, electronic and software sub-systems) to achieve the required functionality and performance. These products are referred to as Coupled Whole Systems. The overall vision of the proposed EPSRC Centre is to develop knowledge, technology and process demonstrators, novel methodologies, techniques and the associated toolsets to provide the capability for the concept design of the coupled whole system based on system design for engineering services.After discussions with the industrial partners, KTNs and all the academics involved in the Centre, it has been decided that the Centre will start with a set of five projects. The projects are of three types, the first one identifies current challenges in the systems design across multiple sectors, the second set of three projects is in TRL levels 2-3 and addresses three major industrial challenges for engineering services across the sectors. This research will develop technology and process demonstrators, design rules and standards to evaluate the system design in order to reduce the engineering services cost later in the life cycle. The third type is more long term and represents TRL levels 1-2. This project will develop technologies that could reduce the need for maintenance and therefore reduce the whole life cost of a high value product. The five initial projects are as follows:Project 1: Study of cross sector challenges in coupled whole systems design (6 mths)Project 2: Reduction of no-fault found (NFF) through system design (3 yrs)Project 3: Characterisation of in-service component feedback for system design (3 yrs)Project 4: Improvement of System Design Process for whole life cost reduction (2 yrs)Project 5: Self-healing technologies for electronic and mechanical components and subsystems (3 yrs)All the initial projects and future ones will use the facilities of a Whole Systems Studio at Cranfield. The Studio will provide instrumentation and facilities to perform experiments in support of the initial and future research projects and develop technology and process demonstrators. The Studio will have a networked computing facility with a data highway based on the OSys integration platform. The platform will initially allow other facilities such as the 3D scanning facility from GOM, Electronics Lab from Durham, IVHM Centre at Cranfield and MRO Shop at Rolls Royce, Derby to be connected with the Studio. In future, other research groups and laboratories will be given access to the Studio as well.The core partners of the Centre are Rolls-Royce, BAE Systems, Bombardier Transport, ARM and the Ministry of Defence (MoD). The partners represent aerospace, defence, railways and electronics sectors. There are 13 other industrial partners representing user companies from defence, information technology (IT), machine tool, and energy sectors and knowledge transfer networks (aerospace, energy and electronics), software vendor, media partner and trade organisations as dissemination partner to support the growth of the Centre.

Planned Impact

The Centre will support existing high value manufacturing companies through technologies and process for improved 'design for engineering services'. The Centre will help aerospace, defence, railways, electronics, energy, high-end automotive and health care equipment manufacturers within the five years. The Centre will also help development of a new UK manufacturing sector in 'engineering services' area. The research and associated activities will help UK to achieve a leading position in the 'engineering services' research internationally. The Centre will also impact the core and industrial partners by improving the system design and engineering services community within the organisations. The UK needs to support its manufacturing sector to grow and secure larger market share in an increasingly challenging global market. Whole system product design and manufacturing with through-life support is a growing business for the UK aerospace, energy, railways, high-end automotive and defence companies. For example, Rolls-Royce has signed a 690 million contract with the UK MoD to support the UK Tornado fleet; they also earn around 60% of their revenue from the engine support team. Energy sector companies for wind and nuclear energies are investing over 30 billion in new build, and that would require engineering services for decades to come. Through life support contracts will require improved service performance in order to reduce the whole life cost. The MoD is looking to share risks more with industry using availability type contracts. A NATO report has suggested a potential whole life cost savings up to 1.4 billion by involving BAE Systems in the maintenance-repair-overhaul (MRO) activities for fast jets. The UK already has 17% of the Global MRO market. The Global market in the aviation industry alone is expected to be around $55 billion by 2014. Similarly, the automotive sector is growing its self-service pay-as-you-go car service where an hourly charge includes fuel cost for the car. This means the support for the car to minimise the fuel consumption is part of the service provider's responsibilities. The business needs to design the whole systems more efficiently and reduce the whole life cost to secure a bigger market share in through-life support global market for the high value products. Support for the business along with the relevant academic excellence has to be established in the UK to sustain growth. The Centre is very timely and relevant to support the growth in the support contracts by improving the product design and by reducing the whole life cost. This will improve competitiveness of UK manufacturing sector. The impact will also be achieved by embedding the research outcomes within the industry sectors. The core partners from the aerospace, defence, railways and electronics sectors will benefit first and then the other 13 industry partners. Three new sectors will be introduced within the Centre, one is energy, one in high-end automotive and the other is health care equipment manufacturing. The Centre will have significant impact on these sectors as well.

Organisations

 
Description Through-life engineering services (TES) can help prepare
the UK automotive industry for future of transport based
on the principle of providing mobility as a service (MaaS).
Our consultations with stakeholders, including vehicle manufacturers, and
consideration of policy frameworks, infrastructure and data, lead us to a number
of recommendations to the Government to enable the creation of a unique British
MaaS offering using TES expertise.

01
Develop system integration capability for through-life of a
MaaS offer
TES for MaaS offers unique opportunity to create a supply chain of OEMs, technology
and service providers, Catapults and R&D organisations/universities that is focused
on system integration with systems level thinking. The development of the right
capabilities needs demonstrator projects that integrate the lifecycle of a MaaS offer
using connected and autonomous vehicles (CAVs). Such project(s) should have
multiple stakeholders to ensure every aspect of MaaS requirements is covered.

02
Set up a National Advisory Board
Set up a National Advisory Board to map the activities that need to be supported
for an exemplar brand of MaaS, such as 'MaaS for Life in complex urban areas'.
The Board should be chaired by an independent person with experience in TES
and MaaS, and include members from city councils, Government, automotive OEM
manufacturers, TES owners and providers, other mobility service providers, insurance
associations, banks, Catapults and universities. The Board should look at the UK
supply chain gap in MaaS and TES, and make recommendations for its development
and capability enhancement. The Board should lead the development of a 'MaaS for
Life' brand for the UK, nationally and internationally, and monitor the demonstrator
projects.

03
Invest significantly in R&D
Significant R&D investment could
build on the UK's track record in
TES, develop prognostics and digital
technologies for MaaS, and contribute
to the development of a 'MaaS for
Life' operating platform. This platform
could be the basis for service
providers to offer innovative services
within a complex urban environment.
The investment could be overseen by
the National Advisory Board.

04
Set up a common
data sharing platform
Set up a data sharing platform (with
common content and data formats) to
support accurate planning of journeys
between different modes of transport:
this should have public organisation
ownership, for example by city
councils. Such a platform would
enable a single ticketing payment
system and promote the success of
MaaS. The MaaS programme should
be rolled out in phases, starting with
cities with a strong public transport
infrastructure.

05
Promote TES for the Industrial Strategy and Sector Deals
TES should be promoted as an enabling technology and business model for the
'Future of Mobility' agenda for the UK's Industrial Strategy and as part of the Sector
Deals in automotive and artificial intelligence (AI). Key technology areas that must
be developed are: degradation-based health and failure monitoring; maintenance
automation; use of AI in condition monitoring and maintenance decision-making; selfdiagnostics
and calibration; self-repair; secure over-the-air upgrades; and design for
through-life engineering services.

06
Promote an open source
platform to enable British
solutions
Unique British solutions must be
supported in the form of an open
source (like Android) platform for
'MaaS for Life'. This could build on
UK expertise in TES in the aerospace
and defence sectors. The MaaS offer
must deliver an agreed environmental
footprint target for the UK, reduce
the unit cost of transport for the
public and be flexible for everyone to
use. A cross-sector platform should
integrate land, air and water transport
and provide for British companies
to export and run services from the
UK, creating new job and revenue
opportunities.

07
Enable TES-related skills development at all levels
In the UK we lack skills both in innovation and in operating competitive 'MaaS for Life' offers. These need to be developed through
apprenticeships and university education, and a culture change in 'service innovation and delivery' needs to be nurtured. The next
generation of leaders need 'systems thinking' and need to be technology aware, with a deep understanding of end-user expectations
and service value propositions. All relevant stakeholders should be engaged to help shape the apprenticeship and education
programmes.

The No Fault Found (NFF) problem has a broad scope that can be divided into systems design, human factors, fault diagnosis and data management. There are currently no standards for NFF management and regulation. Each organisation seems to have their own ad hoc processes.
Organisations do not understand the costs due to NFF and there are currently no benchmarking tools that can be used to evaluate its impact. Intermittent fault occurrences are a major technical root cause of NFF and that there is a clear lack of fundamental understanding of intermittency in electronics.

Thermography can be used to identify damage to complex shaped metal parts from the hot sections of a gas turbine engine. It can penetrate under the thermal barrier coatings and establish if a component is beyond economic repair. The whole process can be automated and thus reduce the need for other labour intensive non-destructive testing techniques.

Initial system design decisions can have a major influence over whole life cost. Systems design for whole life cost reduction is not simple and many trade-offs have to be made. We are debveloping tools to help designers with this problem.
You can design electronics on a chip that will self-repair. It will return to its original functionality over a series of cycles effectively healing a broken system.
We have developed a task decomposition tool that helps identify those maintenance jobs that can be done by robots. The unpredictability of maintenance, for example it is not easy to determine the torque required to undo fasteners when they have been subject to corrosion, makes the use of robots problematic. Identifying parts of jobs where they can be employed means that robot assisted maintenance could become a reality.
We have found out how to hear the initiation of cracks in complex shaped metal parts and thus determine their size, location and rate of growth.
Exploitation Route By broader dissemination events such as the Manufacturing the Future Annual conference
Sectors Aerospace, Defence and Marine,Construction,Digital/Communication/Information Technologies (including Software),Education,Electronics,Energy,Environment,Manufacturing, including Industrial Biotechology,Transport

URL http://www.through-life-engineering-services.org/index.php/home
 
Description Two major development after the Centre funding was completed: PAS 280 on "Through-life engineering services. Adding business value through a common framework. Guide" is published. A new L7 apprenticeship standard is approved (pending funding band) on Through-life Engineering Services. ATI has published their funding strategy for "Through-life Engineering Services" A joint report is published with HVM Catapult on "Through-life Engineering Services for MaaS" The five core projects of the Centre are producing tangible results and the collaborations with our industrial partners have become stronger. We have completed several industrial use cases to add value to the partners. We have published many papers in both peer reviewed journals and at international conferences and now have in production the first book in Through-life Engineering Services which is due to be published in early 2015. We have developed a series of initiatives such as establishing a new international conference, TESConf, with 80 papers and 140 delegates now in its third year, sponsoring a national award in Through-life Engineering Services also in its third year and have held a series of open calls for feasibility studies complementary to our core research and funded 19 proposals involving 11 new universities with the Centre. We have also supported a series of successful proposals valued at £5.7m which have grown the influence of the Centre. The work of the Centre is being given a strong industrial impact by the generation of tools to aid designers of complex engineering products take into account through-life issues. In detail the impact of the work of the core projects is listed below: This work in the No Fault Found (NFF) project aims to quantify the true costs of the NFF phenomenon initially in the RAF fleets. By doing so it is raising the awareness of the size of the problem and through the NFF working group and its annual symposia bringing the message to a wider community. The inclusion of other sectors giving key note speeches at the symposia from Bombardier Transportation and Jaguar Land-Rover has demonstrated the wider extent of the problem and applicability of the research. Work is now focused on the creation of tools and methodologies to help designers reduce the possibility of NFF. It is intended to produce a generically applicable set of guides and rules for the broader design engineering community. The introduction of thermography for service damage inspection within the MRO environment has major potential for impact. We are developing a fundamental capability in automating service degradation inspection which has the potential to significantly reduce the cost of invasive NDT techniques by identifying failing parts earlier in the inspection process and thus reducing current part rejection rates at the later stages of investigation. We have carried out IDEF modelling to identify the current process and are working to propose a revised process to share service knowledge with designers and manufacturing engineers thus enabling them to make better informed decisions. This has led to a future vision for this service process and this now has become a valued final deliverable by our key industrial research partner. From various stakeholder perspectives knowledge can be acquired from the use of bespoke user interface tools which link the user to a series of interconnected libraries and databases. These will store information from the output of various tools, platforms and miscellaneous trending packages which assess, analyse, and present data from various technical sources (MRO events, costs, repair procedures, logistics, user profiles etc). The work on systems design for through-life has raised awareness among the design engineering community of the impact on true costs and the associated issues with early stage decisions. Current work is focused on the creation of tools and methodologies to help system designers with this challenge. While the focus of the practical case studies has been gas turbine design the project will elicit a far more generically applicable set of guides and rules for the broader systems engineering community. The potential impact of the work in self-healing and self-repairing systems is very significant. Despite being at low technology readiness levels its application in the electronics industry could have far reaching effects. Fault incidence is rare and reliability generally high, however redundancy can take up valuable space or add to the weight of platforms which may lead to significant increases in costs. Especially interesting is the application of these new techniques in the flexible printed electronics area where a new project has been launched and an innovation award of £20k has been made by the Centre. Engagement with Industry is of key importance to this research in order to gauge the real challenges present in automation of maintenance activities through robotics. A close relationship with Bombardier Transportation UK has allowed some of the developed research to be tested in the field to give a better understanding of its impact and feedback on where this research can be applied and improved. This covers task classification of a number of train undercarriage maintenance tasks. Maintenance scenarios evolved from those currently encountered by Bombardier within their train maintenance depots are also currently being investigated, for example train brake pad replacement. The potential for impact is huge and this work has led to an investigation of a possible patent application in this area.
First Year Of Impact 2018
Sector Aerospace, Defence and Marine,Communities and Social Services/Policy,Construction,Digital/Communication/Information Technologies (including Software),Education,Electronics,Energy,Manufacturing, including Industrial Biotechology,Transport
Impact Types Societal,Economic,Policy & public services

 
Description ADS MRO and L Committee
Geographic Reach National 
Policy Influence Type Membership of a guidance committee
URL https://www.adsgroup.org.uk/
 
Description ATI Strategy on TES
Geographic Reach National 
Policy Influence Type Participation in a advisory committee
Impact ATI has published a strategy on TES for the Civil Aerospace industry sector.
 
Description BSI Committee GME/21/5 Vibration of machines
Geographic Reach National 
Policy Influence Type Membership of a guidance committee
URL http://www.bsigroup.co.uk/
 
Description BSI Committee GME/21/7 Condition monitoring
Geographic Reach National 
Policy Influence Type Membership of a guidance committee
URL http://www.bsigroup.co.uk/
 
Description BSI Dependability Standards Committee
Geographic Reach National 
Policy Influence Type Membership of a guidance committee
URL http://www.bsigroup.co.uk
 
Description BSI PAS on TES
Geographic Reach Multiple continents/international 
Policy Influence Type Membership of a guideline committee
Impact Cranfield University team is the technical author of the BSI PAS on TES.
 
Description COMADIT committee of the British Institute of NDT
Geographic Reach National 
Policy Influence Type Membership of a guidance committee
URL http://www.bindt.org/
 
Description Chair of CIRP Collaborative Working Group in 'Continuous Maintenance'
Geographic Reach Multiple continents/international 
Policy Influence Type Membership of a guidance committee
Impact International Collaborative Working Group is developing ideas for future research and capture industry requirements globally.
URL http://www.cirp.net
 
Description HealthMAP National Committee, KTN
Geographic Reach National 
Policy Influence Type Membership of a guideline committee
URL https://connect.innovateuk.org/knowledge-transfer-networks
 
Description IET Manufacturing Policy Panel
Geographic Reach National 
Policy Influence Type Membership of a guidance committee
URL http://www.theiet.org/policy/panels/manufac/
 
Description ISO TC108/SC5/WG8 Condition monitoring & diagnostics of machines - general guidelines
Geographic Reach Multiple continents/international 
Policy Influence Type Membership of a guidance committee
 
Description International Congress on Condition Monitoring and Diagnostic Engineering Management COMADEM
Geographic Reach Multiple continents/international 
Policy Influence Type Membership of a guideline committee
URL http://www.comadem.com/
 
Description International Network for Industrial Diagnosis (INID)
Geographic Reach Multiple continents/international 
Policy Influence Type Membership of a guidance committee
 
Description Member of ATI Strategy Committee - Through-life Engineering Services
Geographic Reach National 
Policy Influence Type Participation in a advisory committee
Impact ATI now recognises the need for TES as an enabling technology.
URL http://www.ati.org.uk/ati-tes-survey/
 
Description Member of the Innovate UK 2014 panel on 'Make it BIG in the UK'
Geographic Reach National 
Policy Influence Type Participation in a national consultation
Impact Panel discussion along with four keynote speakers and around 75 participants.
URL https://www.events.ukti.gov.uk/tsb-innovate
 
Description NTC on Advanced Design and Manufacture
Geographic Reach National 
Policy Influence Type Membership of a guidance committee
URL https://connect.innovateuk.org/web/advanced-design-manufacturing-ntc
 
Description Rail Research UK Association
Geographic Reach National 
Policy Influence Type Membership of a guidance committee
URL http://rruka.org.uk/
 
Description TES Council launched
Geographic Reach National 
Policy Influence Type Influenced training of practitioners or researchers
Impact TES Council launched. Chaired by Chris White MP and Sam Turner from HVM Catapult with over 20 industry partners
URL http://www.through-life-engineering-services.org/index.php/home
 
Description TES National Strategy on Engineering Services
Geographic Reach National 
Policy Influence Type Influenced training of practitioners or researchers
Impact Education in Through-life Engineering Services has become more popular.
URL http://www.through-life-engineering-services.org/downloads/Engineering_Services_Strategy_new.pdf
 
Description UKMOD Joint Obsolescence Management Working Group
Geographic Reach National 
Policy Influence Type Membership of a guidance committee
URL https://www.gov.uk/government/organisations/defence-equipment-and-support
 
Description UKMOD Whole Cost Modelling Working Group
Geographic Reach National 
Policy Influence Type Membership of a guidance committee
URL https://www.gov.uk/government/organisations/defence-equipment-and-support
 
Description Atkins-Cranfield Chair
Amount £250,000 (GBP)
Organisation WS Atkins 
Sector Private
Country United Kingdom
Start  
 
Description Autonom Project
Amount £920,000 (GBP)
Funding ID EP/J011630/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 03/2013 
End 02/2017
 
Description Centres
Amount £198,319 (GBP)
Funding ID 900097 
Organisation Innovate UK 
Sector Public
Country United Kingdom
Start 08/2017 
End 03/2018
 
Description Die life improvement
Amount £42,500 (GBP)
Organisation The Royal Mint 
Sector Public
Country United Kingdom
Start 02/2017 
End 04/2017
 
Description EPSRC Impact Acceleration Account
Amount £20,214 (GBP)
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 01/2015 
End 03/2015
 
Description EPSRC Manufacturing Research Fellowship
Amount £957,350 (GBP)
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 01/2012 
End 12/2016
 
Description Engineering Grand Challenges
Amount £502,348 (GBP)
Funding ID EP/N010019/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 12/2015 
End 12/2018
 
Description GCRF
Amount £970,750 (GBP)
Funding ID EP/R013950/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 02/2018 
End 01/2021
 
Description Game-Changing Technologies for Aerospace - Feasibility
Amount £85,132 (GBP)
Funding ID File Ref: 132251 Application number: 65880-452254 
Organisation Innovate UK 
Sector Public
Country United Kingdom
Start 03/2016 
End 12/2016
 
Description Industrial Funding of PhDs
Amount £117,000 (GBP)
Organisation Babcock International Group 
Sector Private
Country United Kingdom
Start 09/2014 
End 08/2017
 
Description Innovate UK
Amount £194,000 (GBP)
Organisation McFarlane Telfer Ltd 
Sector Private
Country United Kingdom
Start 06/2018 
End 05/2020
 
Description MOD Procurement Tasking Order
Amount £29,360 (GBP)
Funding ID FTS4/1000098647 
Organisation Defence Science & Technology Laboratory (DSTL) 
Sector Public
Country United Kingdom
Start 03/2015 
End 03/2016
 
Description Manufacturing automation within the supply chain to ensure patient safety
Amount £125,266 (GBP)
Funding ID EP/N508937/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 02/2016 
End 01/2017
 
Description Metrology and Digital Manufacturing for Servitisation of Manufacturing Machines
Amount £102,000 (GBP)
Funding ID 102787 
Organisation Innovate UK 
Sector Public
Country United Kingdom
Start  
 
Description Operations Excellence Institute
Amount £3,000,000 (GBP)
Organisation Higher Education Funding Council for England 
Sector Public
Country United Kingdom
Start 11/2013 
End 10/2016
 
Description Optimum cost by design
Amount £70,000 (GBP)
Organisation Rolls Royce Group Plc 
Sector Private
Country United Kingdom
Start  
 
Description PLM, IoT and Big Data management for through-life support
Amount £280,300 (GBP)
Funding ID KTP 010558 
Organisation Knowledge Transfer Partnerships 
Sector Charity/Non Profit
Country United Kingdom
Start  
 
Description Platform Grants
Amount £1,228,367 (GBP)
Funding ID EP/P027121/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 04/2017 
End 04/2022
 
Description Scoreboard of Competitiveness of European Transport Manufacturing Industry
Amount £150,000 (GBP)
Funding ID EC 724112 
Organisation European Commission 
Sector Public
Country European Union (EU)
Start 10/2016 
End 03/2018
 
Description Standard development (Innovate UK)
Amount £20,000 (GBP)
Organisation British Standards Institute (BSI Group) 
Sector Charity/Non Profit
Country United Kingdom
Start 11/2017 
End 03/2018
 
Description TOMCAT
Amount £240,000 (GBP)
Organisation Ministry of Defence (MOD) 
Sector Public
Country United Kingdom
Start 04/2013 
End 03/2016
 
Description Adaptive Reliability Target Settings for No-Fault-Found Failure Mode Avoidance SC18 
Organisation University of Warwick
Country United Kingdom 
Sector Academic/University 
PI Contribution £20,000 grant
Collaborator Contribution The objective of this feasibility study is to explore the current challenges and develop them into research questions for building a data-driven PHM system, which will have an essential capability to drive prioritization and refinement of maintenance plans for No-Fault-Found failure mode avoidance.
Impact This initiative will create benefits by proactively prioritizing and refining maintenance plans by providing critical information on the nature and causality of field failures as accurately as possible by utilizing service failure data.
Start Year 2013
 
Description Centre Founding Membership 
Organisation BAE Systems
Department BAE Systems Military Air & Information
Country United Kingdom 
Sector Private 
PI Contribution We have developed use cases, initially with Rolls-Royce, where researchers can address direct industrial problems and industry can gain by having them investigated. The researchers gain by being able to use these use cases in their theses and other publications when suitably anonomised.
Collaborator Contribution These partners contribute management effort to both the Centre Advisory Board (strategic) and the Centre Executive Committee (tactical). They have granted us access to their facilities and experts providing in-kind expertise. They have co-authored publications.
Impact Development of our automated NDT facility. Employment of our Environmental Chamber to resolve NFF issues. Development of case studies for autonomous maintenance and self-healing systems. Testing tools for through-life systems engineering.
Start Year 2011
 
Description Centre Founding Membership 
Organisation Bombardier Inc.
Department Bombardier Transportation
Country Germany 
Sector Private 
PI Contribution We have developed use cases, initially with Rolls-Royce, where researchers can address direct industrial problems and industry can gain by having them investigated. The researchers gain by being able to use these use cases in their theses and other publications when suitably anonomised.
Collaborator Contribution These partners contribute management effort to both the Centre Advisory Board (strategic) and the Centre Executive Committee (tactical). They have granted us access to their facilities and experts providing in-kind expertise. They have co-authored publications.
Impact Development of our automated NDT facility. Employment of our Environmental Chamber to resolve NFF issues. Development of case studies for autonomous maintenance and self-healing systems. Testing tools for through-life systems engineering.
Start Year 2011
 
Description Centre Founding Membership 
Organisation Ministry of Defence (MOD)
Country United Kingdom 
Sector Public 
PI Contribution We have developed use cases, initially with Rolls-Royce, where researchers can address direct industrial problems and industry can gain by having them investigated. The researchers gain by being able to use these use cases in their theses and other publications when suitably anonomised.
Collaborator Contribution These partners contribute management effort to both the Centre Advisory Board (strategic) and the Centre Executive Committee (tactical). They have granted us access to their facilities and experts providing in-kind expertise. They have co-authored publications.
Impact Development of our automated NDT facility. Employment of our Environmental Chamber to resolve NFF issues. Development of case studies for autonomous maintenance and self-healing systems. Testing tools for through-life systems engineering.
Start Year 2011
 
Description Centre Founding Membership 
Organisation Rolls Royce Group Plc
Country United Kingdom 
Sector Private 
PI Contribution We have developed use cases, initially with Rolls-Royce, where researchers can address direct industrial problems and industry can gain by having them investigated. The researchers gain by being able to use these use cases in their theses and other publications when suitably anonomised.
Collaborator Contribution These partners contribute management effort to both the Centre Advisory Board (strategic) and the Centre Executive Committee (tactical). They have granted us access to their facilities and experts providing in-kind expertise. They have co-authored publications.
Impact Development of our automated NDT facility. Employment of our Environmental Chamber to resolve NFF issues. Development of case studies for autonomous maintenance and self-healing systems. Testing tools for through-life systems engineering.
Start Year 2011
 
Description Configuration Management in Through-Life Engineering - Feasibility Study - SC07 
Organisation University of Reading
Country United Kingdom 
Sector Academic/University 
PI Contribution This feasibility study aims to examine configuration management as part of the field of through-life engineering services. This feasibility study provides the basis for a strong research programme on next generation configuration management, rich understandings of the practical challenges of system integrity through-life, interaction between international leaders in configuration management, a benchmark for use in developing new instruments to support them, and enhanced national research capacity in next-generation systems that support innovative manufacturing while maintaining the integrity of engineering data.
Start Year 2012
 
Description Developing Cell Based Flexible Maintenance Systems - Feasibility Study SC11 
Organisation Cranfield University
Country United Kingdom 
Sector Academic/University 
PI Contribution The feasibility study would identify key challenges in the adoption of cellular methodologies to MRO operations, potential improvements in productivity and flexibility that could be achieved, and identify key research questions as a basis for a more substantive study. The research focus is on developing cellular manufacturing approaches that can be applied to the design of layouts, automation, work scheduling and material flow in Maintenance, Repair and Overhaul (MRO) factory floor operations. The feasibility study would provide a platform and justification for further research. It would also act as a demonstrator to help engage industry with more substantive research into the research questions identified in the study. Such research would contribute to the EPSRC Centre by improving MRO productivity.
Start Year 2012
 
Description Electric Vehicle Through-Life Management based on Telematic Data - Feasibility Study SC12 
Organisation University of Sunderland
Country United Kingdom 
Sector Academic/University 
PI Contribution The aim of the proposed project is to investigate how the life span of ultra low carbon vehicles can be enhanced through the application of the latest asset management tools and techniques utilising the rich data available from telemetry and tracking systems. The focus of the work will be battery electric vehicles or battery systems operating in hybrid vehicles. Furthermore the project will focus on fleet vehicles since these have been one of the major early adopters of ultra low carbon vehicles. Little previous work has been conducted in the area of ULCV asset management. Furthermore many ULCVs currently in commercial use have varying degrees of telematic systems installed yet this data is rarely used to support maintenance and life span optimisation. As such this work is believed to be novel, and due to the rapid uptake of ULCVs in commercial trials, extremely timely.
Start Year 2012
 
Description Electromagnetic monitoring of semiconductor ageing SC15 
Organisation University of York
Country United Kingdom 
Sector Academic/University 
PI Contribution £20,000 grant
Collaborator Contribution The ability to monitor the through life ageing of semiconductor devices is useful to provide system health level information. In complex electronic systems built-in monitoring can be used to dynamically allow for ageing and other performance factors - for example, by monitoring critical timing paths then adjusting the clock frequency and supply voltage in a digital processor to ensure adequate timing margins. These methods require physical connection and/or the incorporation of additional circuitry. Here we aim to determine the feasibility of methods of monitoring age related performance effects which require no connection to the circuit and no additional circuitry in the design.
Impact Paper Submitted to EMC Europe 2014
Start Year 2013
 
Description Fault-tolerant strategies for printable electronics SC19 
Organisation Durham University
Country United Kingdom 
Sector Academic/University 
PI Contribution £20,000 grant
Collaborator Contribution This project aims at modelling and experimentation of design techniques for fault tolerance and built-in detection for intermittent and permanent errors caused by random faults. Efforts are made to extrapolate existing knowledge to printed circuits with advisement from the CPI National Centre for Printed Electronics.
Impact None as yet
Start Year 2014
 
Description Integrating spare parts planning with health monitoring SC16 
Organisation Cranfield University
Country United Kingdom 
Sector Academic/University 
PI Contribution £20,000 grant
Collaborator Contribution We assessed the business case of a prediction model for the scraped parts and the repaired nozzle guide vanes of the Trent 800 engine manufactured by Rolls Royce and used by the Boeing 777. A Monte Carlo analysis that gives results on the possible cost savings when using this prediction model was developed.
Impact The results described in this paper show the potential for improvements in terms of cost cutting when looking at the maintenance process of a civil aircraft engine.
Start Year 2013
 
Description Integrity and Through-Life-Degradation of Electrical Wiring - Feasibility Study - SC08 
Organisation University of Lincoln
Country United Kingdom 
Sector Academic/University 
PI Contribution The  feasibility  study  will  explore  how  the  current  generation  of Intermittent  Fault  Detection  (IFD)  tools  can  be  used  to obtain  an  assessment  of  the  long_term  integrity  of  Electrical  Wiring  Interconnection  Systems  (EWIS) and of candidate electrical machine and associated power electronic component and, or inverter technologies.  This work will present results on the first scoping studies to broaden the current applicability of a prototype United Synaptics Corporation analysis system and provide and report on the possible merits of extending the underlying concepts to address the more challenging issues of enhanced diagnostics and prognostics.
Start Year 2012
 
Description Machine Tool Loan 
Organisation DMG Mori Seiki Co.
Department DMG Mori UK
Country United Kingdom 
Sector Private 
PI Contribution We are researching remote condition based maintenance of machine tools
Collaborator Contribution Loan of an NT1000 machining Centre
Impact Machine tool installed at Cranfield
Start Year 2014
 
Description Maintenance of complex engineering systems - Feasibility Study - SC01 
Organisation University of Cambridge
Country United Kingdom 
Sector Academic/University 
PI Contribution This study will develop a proposal which will explore how condition-monitoring data, production data, and product quality data, can be captured, combined and used to improve the knowledge of the behaviour of an automated manufacturing system, thereby allowing to develop better maintenance programs that maximise the value provided by the system, while still meeting customer?s requirements in terms of product quality and demand. This feasibility study led to the development of a responsive mode proposal to the EPSRC called OTTIMA - Optimal Through-Life Condition-Based Maintenance of Complex Automated Manufacturing Systems based on Auto-ID / smart sensing technologies
Start Year 2011
 
Description Manufacturing Driven Design Allowables and Failure Mechanisms - Feasibility Study - SC03 
Organisation Queen's University Belfast
Department School of Mechanical and Aerospace Engineering
Country United Kingdom 
Sector Academic/University 
PI Contribution This study will develop a new understanding of how varying impacts in service relate to design damage allowables in advanced structural composites to bridge the knowledge gap between design standards and real airframe structures. The purpose of the feasibility study is to scope in more detail the technical issues related to the research and to clarify the overlapping and collaborative aspects of the research area. The feasibility study will undertake some impact analysis of composite plates and will scope the full investigation, clarifying technical advances and their potential value.
Start Year 2011
 
Description Multifunctional hierarchical composite structures utilising carbon nanotube webs SC13 
Organisation Queen's University Belfast
Country United Kingdom 
Sector Academic/University 
PI Contribution £20,000 Grant
Collaborator Contribution The aim of this study was to explore the feasibility of using carbon nanotube (CNT) webs to create superior lightweight and multifunctional carbon-fibre reinforced polymer (CFRP) composite aerostructures with emphasis on structural health monitoring, integrated lightning-strike protection and anti-icing capability as well as improving interlaminar shear strength.
Impact This project has achieved outstanding progress in establishing the capability in-house at QUB MAE to conduct research and development in to CNT-enhanced CFRP composites for aerospace applications. This capability has also gained a substantial commitment from the School to establish CNT synthesis, and is well advanced in establishing productive collaborations with a number of world-leading institutions and researchers in the field.
Start Year 2013
 
Description New Tier 1 Centre Member 
Organisation Babcock International Group
Country United Kingdom 
Sector Private 
PI Contribution Supervision of three PhD Students working on projects of direct relevance to the client. Consultancy work on risk assessment in costing service and support contracts.
Collaborator Contribution Active participation in the PhD areas of study. Membership of the Centre Executive and advisory boards. Participation in the development of a TES National Strategy through workshops. Membership of the TES National Strategy Steering committee.
Impact Case studies have been carried out by the PhD students
Start Year 2015
 
Description Nuclear Life Management - Feasibility Study - SC02 
Organisation University of Manchester
Department Dalton Nuclear Institute
Country United Kingdom 
Sector Academic/University 
PI Contribution This feasibility study draws together a team with unique world-class capabilities on manufacturing, through-life engineering services and nuclear technology. This team has produced a proposal, the DOMMAIN project, to tackle the difficult problem of how to provide the capabilities to quantitatively monitor and estimate the degradation of nuclear reactor components, to more effectively manage component usage and repair and thereby to optimize plant availability and to support eventual plant life-time extension. This study led to the responsive mode proposal to the EPSRC entitled Degradation Optimised Management for Manufacturing In Nuclear (DOMMAIN)
Start Year 2011
 
Description Real-time Monitoring of Turbine Blade and Generator Shaft Alignment - Feasibility Study SC06 
Organisation Durham University
Country United Kingdom 
Sector Academic/University 
PI Contribution This study aims to establish a methodology of separate assessment in real-time of wind turbine shaft alignment and blade alignment using lasers The objective of this research is focussed on using laser-based metrology techniques to capture the positional changes of wind turbines in service and aligning drivelines in wind turbines. In this way the mechanical operation, and therefore the aerodynamic design and loading predictions, of the turbine can be more accurately predicted and thus lead to greater optimisation and improved efficiencies.
Start Year 2012
 
Description Risk-based Bayesian Sequential Decision Making for Autonomous SC14 
Organisation University of Sheffield
Country United Kingdom 
Sector Academic/University 
PI Contribution £20,000 grant
Collaborator Contribution The proposal delivers a demonstration of capability, through application to today's Industrial problems, with an intention to expand into future work delivering intelligent diagnostic capability to next-generation autonomous systems. The proposal immediately delivers near-term opportunities for improved industrial system through-life economic value. The value is delivered through a combination of reduction of diagnostic false alarms (minimising no fault found instances in maintenance) and minimisation operational impact of fault events.
Impact The proposed work will output a health monitoring algorithmic framework for managing the trade-off between detection accuracy and detection timeliness based on an expectation of risk and benefit in a decision given an asset's operating mode. The methodologies developed are essential to any application where decision making based upon a diagnostic assessment of heath state is required. In addition to the expected immediate benefit, the work will develop a large-scale proposal for a comprehensive and generic framework for autonomous risk-based decision making.
Start Year 2013
 
Description TES Club Members 
Organisation Airbus Group
Department Airbus Defence & Space
Country United States 
Sector Private 
PI Contribution We have run an MSc student group project with Intelligent Energy. We have run an MSc Individual Project with Cassidian Test and Services.
Collaborator Contribution Both companies have hosted projects within their organisations.
Impact Vautravers, A. (2014) "Optimisation of sensor placement for a UAV fuel system to reduce No Fault Found" Supervisors: S. Khan, P. Sydor, A. Shaw, Sponsor: Cassidian Test and Services
Start Year 2014
 
Description TES Club Members 
Organisation Intelligent Energy
Country United Kingdom 
Sector Private 
PI Contribution We have run an MSc student group project with Intelligent Energy. We have run an MSc Individual Project with Cassidian Test and Services.
Collaborator Contribution Both companies have hosted projects within their organisations.
Impact Vautravers, A. (2014) "Optimisation of sensor placement for a UAV fuel system to reduce No Fault Found" Supervisors: S. Khan, P. Sydor, A. Shaw, Sponsor: Cassidian Test and Services
Start Year 2014
 
Description Through-Life Condition Monitoring of Electric Drives and Batteries in Electric Vehicles and Plug-in Hybrid Electric Vehicles SC17 
Organisation Queen's University Belfast
Country United Kingdom 
Sector Academic/University 
PI Contribution £20,000 grant
Collaborator Contribution This review of the state-of-art through-life condition monitoring (CM) techniques used for electrical machines, power converters (including IGBTs and capacitors) and batteries in electrified vehicles (EVs) was conducted as part of a feasibility study on Through-Life Condition Monitoring of Electric Drives and Batteries in Electric Vehicles and Plug-in Hybrid Electric Vehicles and should be helpful to identify key challenges to integrate CM circuitry (for monitoring electrical motors, power converters and batteries) into existing on-board diagnostic (OBD) system of electric vehicles.
Impact Upon the completion, this project will propose a full condition monitoring system for monitoring electrical drives used in EVs/HPEVs.
Start Year 2013
 
Description Through-Life Support Cost Reduction and Improved Health Management Technologies for Radio Frequency Electronic Systems SC05 
Organisation Cranfield University
Country United Kingdom 
Sector Academic/University 
PI Contribution £20,000 grant
Collaborator Contribution A study was conducted to establish the current state-of-the-art of health management technologies for RF electronic systems. The investigator also used the feasibility study funding to visit a number of manufacturing and through-life support service companies for radar systems and discussed through-life research needs with them. He also used the funding to make contact and visit appropriate research universities to discuss a research proposal with EPSRC. He also spent time discussing the through-life engineering aspects of radar systems with the Technology Strategy Board Knowledge Transfer Networks and National Microelectronics Institute (NMI) to understand the national importance of this proposal and possible future networking activities. The output from these discussions will be used to develop an exploitation plan for the EPSRC proposal.
Impact Final Report has been written and this is available to Centre Partners and Industrial Members
Start Year 2011
 
Description Through-life Support Cost Reduction and Improved Health Management Technologies for RF Electronic Systems - Feasibility Study SC05 
Organisation Cranfield University
Department Integrated Vehicle Health Management Centre
Country United Kingdom 
Sector Academic/University 
PI Contribution This feasibility study will make the case for developing health monitoring technologies for radar systems in the newly-established EPSRC Through-life Engineering Services Centre. The proposed study will look at the best practices in implementing health monitoring capabilities in RF sensor and embedded processing electronics, and will obtain information regarding subsystems and systems from domain experts, perform effectiveness analysis of the potential diagnostic/prognostic intervention capabilities and strategies for RF/embedded electronic systems, and perform a best practice/literature investigation of HUMS, etc. technologies for electronic and RF systems.
Start Year 2011
 
Description Through-life assessment of high-performance microsystems - Feasibility Study - SC04 
Organisation Cranfield University
Country United Kingdom 
Sector Academic/University 
PI Contribution This study aims at assessing the servicing challenges associated with high-performance microsystems, such as maintenance, repair, upgrade, whole-life cost and obsolescence. It aims at investigating how identifying associated services would influence design and manufacturing such that service performance and cost could be optimised. - Identifying service challenges for non-disposable, high performance microsystems. - Investigating design approaches to minimise service requirements for such systems, and how such approaches would affect the fabrication technique. - Assessing possibilities of failure or performance deficiency in high-performance microsystems, and how mitigating such risks would influence design and manufacturing.
Start Year 2011
 
Description Tier 2 industrial members 
Organisation British Standards Institute (BSI Group)
Country United Kingdom 
Sector Charity/Non Profit 
PI Contribution We have carried out research into the need for and structure of standards in the TES domain
Collaborator Contribution As well as their cash contribution BSI have supported our annual conference and helped to fund Professor Paul Tasker, a Royal Academy of Engineering visiting Professor
Impact TESConf 2012, 2013 and 2014 papers. Industrial workshops at TESConf 2014.
Start Year 2012
 
Description Tribology and through-life maintenance strategies for premature wind turbine gearbox bearing failures ? Feasibility Study SC10 
Organisation University of Southampton
Country United Kingdom 
Sector Academic/University 
PI Contribution The feasibility study will develop collaborations between the two national centres in two different areas to generate synergy between multiple research areas including tribology and through-life engineering. The aim of the feasibility study is to establish collaborations between nCATS and CIMTES in order to develop joint programmes and proposals in tribology and through-life maintenance strategies for premature wind turbine gearbox bearing failures.
Start Year 2012
 
Title Self-repairing electronic data system 
Description The present invention relates to the field of cellular automata, bio-imitation and fine-grained self-reconfigurable 5 hardware. In particular it mimics the biological repair mechanism "morphogenesis". More particularly it uses a convergent cellular-automaton as the means of determining the behaviour of each cell with respect to a program for the whole device. 
IP Reference GB2468269 
Protection Patent granted
Year Protection Granted 2013
Licensed No
Impact US Patent granted in 2013 US8386844
 
Description TES Award 
Form Of Engagement Activity A magazine, newsletter or online publication
Part Of Official Scheme? Yes
Geographic Reach National
Primary Audience Industry/Business
Results and Impact Year on year more companies are participating in this event and interest in Through-life Engineering Services is growing

SME Energy companies entering the competition this year
Year(s) Of Engagement Activity 2012,2013,2014,2015,2016
URL http://www.through-life-engineering-services.org/news-and-events/news/the-manufacturer-awards-2014
 
Description TES Knowledge Hub 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Policymakers/politicians
Results and Impact These are a series of six monthly meetings to a closed group of senior directors of industry, politicians and civil servants to discuss and explore the problems and concerns of Through-life Engineering Services across multiple industrial sectors with a view to identifying key issues and associated collaborators to further the Centre's research agenda.

The broad issue of Through-life Engineering Services has been brought to the attention of the All Party Parliamentary Manufacturing Group as has the work of the Centre in this regard.
Year(s) Of Engagement Activity 2014
URL http://www.through-life-engineering-services.org/index.php/partners-and-work-with-us/dependabilty-kn...
 
Description TES Summer School 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? Yes
Geographic Reach International
Primary Audience Postgraduate students
Results and Impact This cross disciplinary course provided access to the leading research academics in the EPSRC Centre and involved significant hands on exposure to the technologies in the TES Studio and the Integrated Vehicle Health Management (IVHM) Laboratory. The course included extensive group work and workshop style learning and enabled the creation of an international network of the attendees.

Participation in the Summer School has attracted companies not members of the Centre to enquire about joining
Year(s) Of Engagement Activity 2013,2014,2015
URL http://www.through-life-engineering-services.org/index.php/courses/summer-school