Overcoming Challenges Associated with Developing Industrial Prognostics and Health Management Solutions

The development of prognostics and health management solutions in the manufacturing industry has lagged behind academic advances due to a number of practical challenges. This work proposes a framework for the initial development of industrial PHM solutions that is based on the system development life cycle commonly used for software-based applications. Methodologies for completing the planning and design stages, which are critical for industrial solutions, are presented. Two challenges that are inherent to health modeling in manufacturing environments, data quality and modeling systems that experience trend-based degradation, are then identified and methods to overcome them are proposed. Additionally included is a case study documenting the development of an industrial PHM solution for a hyper compressor at a manufacturing facility operated by The Dow Chemical Company. This case study demonstrates the value of the proposed development process and provides guidelines for utilizing it in other applications.