Adjustments and innovation have long been a hallmark of the vehicle maintenance industry. However, with dramatic changes reshaping the industry occurring much more frequently, it has become paramount that shops strategically embrace changes in order to not just survive, but prosper.
That is a considerably formidable task.
The accelerated rise in advanced onboard technologies; the increasing availability of vehicle data and information from the proliferation of onboard sensors and telematics systems; the growth of increasingly intelligent, inter-connected and instrumented vehicles; the expanding regulatory requirements on fuel economy and emissions; the evolution of autonomous vehicles and more are changing the rules of the vehicle maintenance and repair game.
This article is intended to help you better plan for the future. It is a roundup of views from various organizations involved in the fleet maintenance industry – including OEMs and suppliers – on what they feel are the most transformative and disruptive technology trends impacting vehicle maintenance over the next five years.
[ other head ] Vehicle connectivity and customer expectations
Catherine Auckland
Director, Aftermarket Marketing
Daimler Trucks North America (www.daimler-trucksnorthamerica.com) produces and markets Class 5 to 8 trucks and is the leading heavy duty truck manufacturer in North America.
Two of the biggest trends that will have an impact on maintenance now and in the next five years are vehicle connectivity and customer expectations. The “connected truck” is not just a buzzword in the industry. It reflects a significant turning point.
Trucks are becoming more efficient and safer through connectivity, as well as easier to maintain. At the same time, lower margins, increased competition and the speed of business are adding new demands and pressures for owner operators and fleets who, in turn, expect much more from their service teams.
These ever-increasing expectations and new technologies are shaping the industry in a significant way.
Over the past five years, vehicle connectivity, in the form of remote diagnostics, has become commonplace among commercial vehicle OEM offerings. DTNA introduced Detroit Connect Virtual Technician more than five years ago, and other truck and engine OEMs have followed suit with their own remote diagnostic products.
While the trend toward offering remote diagnostics began with commercial trucks, the school bus industry is catching on as well, as they implement OEM-installed connectivity for the first time. DTNA’s Thomas Built Buses will be the first school bus OEM in the industry to debut factory-installed engine diagnostics with the 2018 introduction of the new Detroit DD5 engine equipped with Detroit Connect Virtual Technician.
THE SERVICE EXPERIENCE
The advent of the connected truck and bus are changing the commercial vehicle service experience. Diagnosing engine and component issues has never been easier, and near real-time monitoring now gives maintenance technicians the data to better understand the severity of the fault issue and the diagnostic details to help repair the issue correctly the first time.
Virtual Technician is supported by the experts at the Detroit Customer Support Center (DCSC), who provide fleets a deep dive into severe fault issues to help technicians get the vehicles back on the road faster, improving uptime. Fault data transmitted by Virtual Technician can help pinpoint a problem before it becomes a major issue that requires extensive repair and downtime.
As connected vehicle services become even more advanced, there’s even greater potential to be even more integrated into the service experience.
Fleets are also becoming much more sophisticated in how they consume vehicle fault data transmitted by connected vehicle platforms, and OEMs recognize this demand. When Virtual Technician was introduced, it delivered fault notifications and diagnoses via email. Now, DTNA is evolving its technology by launching the new Detroit Connect portal that will deliver vehicle fault data in an easy-to-use interface, enabling fleets to have instant access to much more detail.
They’ll be able to easily see their vehicle’s fault event history so they can recognize and address fault patterns that might lead to greater problems down the road. They will have access to the same “ring buffer” data – the 75-second recording of key sensor data that tells the full story of what was going on with the truck – which the DCSC uses when diagnosing severe fault events. Fleets will have even more actionable data to make the best maintenance decisions possible to keep their trucks up and running.
Eventually, vehicle connectivity could potentially offer even more in improving the maintenance experience. Concepts like predictive maintenance, pre-approved warranty, automated repair order generation and more – using data transmitted from the vehicle remotely – could be ideas that are not far-fetched in the not-so-distant future, given the potential for further advancements in vehicle connectivity.
INDUSTRY PRESSURE
Other factors that will shape the fleet maintenance industry are customer expectations and increasing industry pressure. Goods must be moved faster, margins are slimmer and trucks must maintain uptime as much as possible.
For maintenance technicians, that equates to increased pressure to minimize downtime, better communicate repair status and maintain a higher level of customer service that has not been the expected in the past. Over the next few years, this pressure will continue to increase.
To address the need, DTNA’s service network – which includes Freightliner, Western Star and Thomas Built Buses dealerships and Detroit distributorships – is in the midst of a service evolution. DTNA has invested millions of dollars in the dealer and distributor network and in technology to improve uptime and enhance the customer experience.
A commitment to increasing parts availability, improving shop and service efficiency, supply chain enhancements, streamlined customer communication and a cultural shift in its network will continue to push a new standard of service.
PARTS MANAGEMENT
This focus on efficiency to maintain uptime has changed and will continue to change parts ordering and management processes. Parts distribution centers (PDCs) across the country are increasing in scale as millions of dollars of parts move through them daily.
But PDCs are only part of the story. Dealers, distributorships and repair shops are improving uptime by simplifying and expediting the parts ordering and delivery process through a myriad of support tools, such as inventory management systems, dedicated delivery and e-commerce tools.
The expectation to have parts on hand quickly is becoming the norm and this is creating added stress for service technicians and parts suppliers. It’s no longer acceptable for trucks to sit in service bays for days on end, waiting for parts, let alone for diagnosis.
New technology, advanced telematics and significant investments in service networks and the supply chain are revolutionizing the industry. With OEMs like DTNA leading the charge, the future of service will become more effective and efficient than ever before, leading to increased uptime and smoother logistics for fleets across the country.
[ other head ] The impact of market needs
David McCleave
Director of Aftermarket
&
Steve Berry
Global Field Service Director
Hendrickson (www.hendrickson-intl.com) is a leading manufacturer and supplier of medium and heavy duty mechanical, elastomeric and air suspensions; integrated and non-integrated axle systems; auxiliary lift axles systems; parabolic and multi-leaf springs; stabilizers; and bumper and trim components to the global commercial transportation industry.
Over the next five years, our industry will be inundated with new interconnected smart technology and products. This is driven by a myriad of factors that include, but are not limited to, the demand to extend product life, reduce maintenance costs and improve uptime – all of which enables lower total cost of ownership.
Smart technology and products are also driven by the current and long-term outlook for skilled technicians, the safety and compliance of drivers and fleets and to create a competitive advantage for new truck and trailer sales, along with capturing the parts and service requirements.
Hendrickson continues to develop and design systems that transform the way equipment will be maintained in the areas of air inflation, controls, weight bias liftable axles, mono leaf spring and steer axle technology and wheelends, to name a few. Technology trends may seem like an industry disrupter, but it is really driven by the market needs.
For instance, skilled technicians, available billable time and job training is one of the biggest challenges we see over the next few years. Our solutions, such as longer-lasting wheelends and lower maintenance systems, remove some of the burden on technicians.
We all strive for equilibrium. Smart technology and products, combined as a whole, can lower the time requirements (demand) to match the technician available billable hours (supply).
EDUCATION
The availability of skilled technicians is one of the top concerns of fleets today. A valuable technician must be able to analyze and perform a repair correctly the first time within or better than the SRT (Standard Repair Time). To facilitate this, technicians require proper education, information and tools right at their fingertips.
With a challenging technician base, the industry requires a more automated and connected process of parts identification, service and available training. Things such a such as quick, short repair videos, easy-to-find and understand technical information and timely assistance when required.
Next year, Hendrickson will launch its first online Education Portal in North America. This will be accessible 24 hours a day 7 days a week through the company website. This portal has been designed around three simple platforms requested from our customers:
- Make it quick and simple,
- Provide short two- to three-minute product repair videos.
- Provide an administration function with the ability to test technicians.
As in everyday life and business, the key is obtaining correct information quickly. Having access to electronic tools and maintenance and repair information while performing the job is a trend that will be redefined in the future as the virtual technician.
TIRE COSTS
The safety and compliance of drivers and fleets also pushes technological advances that will reshape maintenance trends. Hendrickson’s TIREMAAX PRO automatic tire pressure control system for trailers and ULTRAA-K with ZMD Zero Maintenance Damping air springs are two examples.
Driving down tire maintenance costs is a top concern for all fleets, and the TIREMAAX PRO was designed to address this concern. It will inflate or deflate the tire to maintain the desired pressure enabling longer tire life and peace of mind that tires are inflated at the proper levels for roadside inspection compliance.
Shocks present another maintenance area that drives costs up due to replacement requirements, or costs associated with non-compliance to regulatory mandates. ZMD is an air spring that combines the characteristics of an air spring with the characteristic of a shock. By eliminating the shock absorber all together it removes a maintenance item, lowers maintenance costs and improves regulatory compliance without compromising the performance of the system.
AFTERMARKET
Smart systems and products can also affect trends on where parts and services can be found and performed. Closed systems force fleets to visit the OEM dealer. Open systems allow fleets to shop the OES (Original Equipment Suppliers) and independent aftermarket channels to garner the most competitive price for parts and service.
Approximately a year ago, a heavy duty right to repair memorandum of understanding was signed between independent aftermarket associations and heavy truck OEMs. The independent aftermarket will now have access to OEM-controlled information that will complement the OEMs, independent repair facilities and fleet customers.
Three maintenance trends come to mind:
1. Open competition will drive maintenance costs down for fleets.
2. Addresses the shortage of available skilled technicians by accessing a larger pool (both channels).
3. Drives further innovation. Since information, technology and tools are openly available, maintenance and repair operations will create programs to keep customers coming back to them.
This will accelerate the parts, service, and maintenance technology trends in the heavy duty market.
Our industry will continue to be inundated with new interconnected smart technology and developments at a very rapid pace. These technological advances in products, systems and subsequent maintenance trends, as outlined, are manifested by listening to the marketplace, technicians, fleets, dealers, independent parts and service providers and many others.
[ other head ] Connected vehicle technologies
Rachel Suttle
Supervisor, Connected Vehicle Strategies
Hino Trucks (www.hino.com) assembles, sells and services environmentally-friendly Class 4 to 7 conventional and cabover commercial trucks in the U.S.
When thinking of the future of the automotive and trucking industry, it is easy to jump to self-driving trucks barreling down the highway. But the connected vehicle technology that allows for this innovation has some pretty exciting building blocks that are currently available to fleets. The building blocks are in the basics of telematics, which is taking fleet management to the next level of efficiency.
OEMs are increasingly seeing the value in offering fleets connected vehicles, as demonstrated this year when Hino Trucks offered the connected vehicle platform INSIGHT as a standard on all new trucks, expanding on what the connected vehicle really means to fleets.
The Cloud, connectivity, mobility and big data are all concepts that are impacting nearly every industry. While many have a general sense of what it all means, really leveraging new technology in the trucking industry is on the brink of expansion.
FLEET OPTIMIZATION
When fleets think of a connected vehicle, they typically think of dots on a map and GPS tracking, though telematics has truly progressed beyond track and trace. Through rich data, fleets are able to obtain information on their vehicles’ health, driver behavior and vehicle efficiency, allowing true optimization of their fleets.
According to Frost & Sullivan, fleets using telematics can experience a:
- 15 percent increase in productivity.
- 25 percent decrease in fuel cost.
- 20 percent increase in vehicle utilization.
- 30 percent reduction in idle time.
Each of these factors impacts the bottom line operation costs for a fleet.
In addition, changing legislation, such as electronic logging devices and hours of service, are pushing fleets to adopt technology more quickly. A connected vehicle as a standard allows fleets to comply immediately, without the research and added investment for their fleets.
STANDARDIZATION
Traditionally, OEMs have left the choice of telematics selection to fleets, waiting for them to realize the value on their own. As the importance of data increases, OEMS are beginning to see the value in offering telematics as standard, or at the very least including embedded hardware in the vehicles.
With this comes expanded capabilities. These include industry benchmarking and OEM specific data points, such as diesel exhaust fluid monitoring and manual regeneration monitoring, which contribute to vehicle maintenance.
With so much data available, the challenge facing fleets is what should they be looking at and how do they leverage hundreds of data points. This is where having a consistent user experience and understanding a fleets’ objectives play a role. Seeing this as a concern, OEMs standardizing their solutions allows easy execution of fleet goals.
DTCs
As an extension of telematics, the industry is seeing an increase in remote diagnostics, which is included in the INSIGHT platform. Remote diagnostics means monitoring any diagnostics trouble codes (DTCs) on the vehicle and alerting the fleet to the severity and suggested action for the truck.
Historically, DTCs have not been shared with fleets, but doing so is opening transparency between the OEM and fleets. Providing actionable data such as this allows prevention of catastrophic failures and improves uptime for fleets.
Knowing that an engine light is a low priority and the driver can continue the route for the day saves time and stress. Also knowing that a fault could begin to de-rate the engine allows the driver to get to safety.
The OEM goal is to keep trucks on the road and maximize the vehicle’s uptime.
CONNECTED DEALERS
The connected vehicle can expand beyond just monitoring vehicle health and driver behavior. With OEMs standardizing the connected vehicle, it offers the opportunity for a connected dealer.
INSIGHT Case Management, for example, is a program that completes the circle between telematics and remote diagnostics, providing clear communication and transparency between all parties, creating the ultimate ownership experience.
When a fault code is triggered by remote diagnostics, a case is opened with the INSIGHT Diagnostic Center. Then, the case can be sent to the dealer – along with the diagnostic data, parts lists and repair operations – before the truck has even arrived at the dealership, allowing for proper preparation of service. Also, quick actions and easy communication tracking allows all records to be in one location for the fleet.
Now, not only are fleets able to monitor driver behavior and vehicle health, but also their service experience.
OVER-THE-AIR
Growth in acceptance of telematics, remote diagnostics and case management, allows future functionality to be built over the next few years.
A major enhancement that has been grabbing headlines recently is over-the-air engine reprogramming. While some OEMs have made announcements regarding their over-the-air intention, it is not practiced or available to the majority of fleets at this time.
Similar to how one might receive streaming updates on their phone, customers can update the computer module(s) within the truck. This is an enhancement that has a real impact on how fleets operate.
Unlike phones, updates to trucks are far and few between, but the opportunity for fleets to complete updates in house has a huge impact on uptime.
Currently in its infancy in the industry, but fleets will see more headlines and first-hand experience over the next five years regarding over-the-air updates.
When thinking of connected vehicles, it is easy to get swept up in the prospects of autonomous features and self-driving trucks. While the prospect is exciting, don’t overlook all of the connected vehicle basics that are available to improve fleet efficiency and contribute to a well-maintained vehicle. Telematics, remote diagnostics and case management are an expanding base that offer value for fleets now.
[ other head ] Disruption from big data
Mark Reiter
Vice President, Customer Support
Navistar (www.Navistar.com) is a holding company whose subsidiaries and affiliates produce International brand commercial and military trucks, proprietary diesel engines and IC Bus brand school and commercial buses. An affiliate also provides truck and diesel engine service parts.
The Internet of Things, and the big data derived from it, represents a huge new opportunity for fleet maintainers. The potential for right-timing maintenance – to avoid both catastrophic breakdowns and excessive downtime for unneeded vehicle maintenance – has never been greater. Neither have the economic stakes.
Why? Because today’s new trucks have never been more technologically advanced or more costly. Neither have their cargoes. Some observers estimate that today, every day that a typical over-the-road vehicle is not actually going over the road, its owner loses roughly $1,000.
So unnecessary maintenance is as bad, in its own way, as catastrophic breakdowns. Getting trucks off the road only when they need it, and getting them back on the road as soon as possible, are major economic opportunities for fleets.
NEW PARADIGM
Maintenance personnel are accordingly moving rapidly to take advantage of the more precise approaches now available through big data. The most important source of such data is the vehicle itself.
The industry is moving to a new paradigm:
- The historical model is “reactive” maintenance. Based on low visibility into potential problems, fleets were used to simply reacting when problems arose. If it broke, you fixed it.
- A more recent model is “proactive” maintenance. If there was a problem with a given part, that part was replaced across the board.
- Today’s disruptive approach is “predictive” maintenance. Not simply replacing every potentially at-risk part, but using knowledge of the vehicle itself to determine whether a failure is likely, given the way each vehicle is being used and the stresses it is putting on that part.
Customers tell us they’ve saved lots of money by taking the predictive approach. What has made this possible are telematics and other connected services that result in a steady stream of data coming from the vehicle – and analytics that make the most of that data.
“SYNTHETIC” FAULT CODES
Analytics help assess the way a vehicle is used and how that may potentially affect a given part. Based on a vehicle’s application profile, truck users can determine whether a given part is likely to break down on that vehicle – thus determining how important and time-sensitive a repair or part replacement might be.
Advance notification is likely to come in the form of a “synthetic” fault code – an analytics-based construct that is designed to trigger a warning, typically before any specific failure occurs. Triggers can be based on a vehicle’s presence in a specific geographic area, when it reaches certain mileage intervals, when it has spent a given number of hours in service or many other parameters.
Based on such precise insight, a given part may not need to be replaced in a given instance. The financial impact can be significant because of both reduced maintenance costs and improved uptime.
Smart maintenance practices are especially important to uptime. Today’s detailed, advance knowledge can both head off unscheduled, catastrophic maintenance problems, plus prevent overreaction in the other direction, by reducing unnecessary maintenance and limiting repairs to the vehicles that actually require them.
Data and analytics remove the guesswork in vehicle maintenance, allowing fleets to make an educated decision about where and when to take a vehicle out of service for repairs or maintenance, or whether to:
1. Finish the delivery and take care of the issue during the next scheduled maintenance.
2. Deliver the current load and then get the truck serviced afterward.
3. Stop the truck immediately and get it serviced right away to avoid progressive damage.
This keeps trucks moving and making money whenever possible.
WRITE-UP PROCESS
Big data – including vehicle-specific big data – is also critical to speeding repairs when they do prove to be necessary. One major area of opportunity is the write-up and diagnostic phase.
Today, mobile applications can capture data from the vehicle upfront, including a “health report,” that can be automatically generated using telematics data. Not just before a technician examines the vehicle, but before a service advisor even speaks to the customer.
New mobile input tools can also capture information from other sources, including specific customer complaints and photographs of the vehicle. When this information is captured more quickly, and analyzed quickly through analytics tools, it speeds the repair process, enhances its effectiveness and increases the likelihood that all current issues will be addressed, not just the one flagged by the customer.
Advanced input from telematics systems can also support a service we refer to as “smart repair routing.” This is where the combination of data and analytics – including the vehicle’s GPS location – not only enables diagnosis of a problem, but provides the driver and maintenance manager with a list of the best repair options and refers them on to service locations that have:
- The requisite repair parts.
- An open service bay.
- A qualified technician at the ready.
We can envision a day in the not too distant future when a servicer and customer will initiate a dialogue based on a diagnostic trouble code and will be able to accurately diagnose and provide a repair estimate that details the time, parts and labor involved – all before the truck even gets to the service bay.
AVAILABILITY
The Internet of Things will also increase the likelihood that the right combination of parts and service will be readily available.
A steady stream of data from the vehicle will ultimately enable analysis of trends in parts requirements. Gone will be the days of parts shortages, because customers, dealers and manufacturers will be communicating openly through telematics to ensure that inventories can meet demand.
Telematics-based tools like these are increasingly moving our industry into the predictive approach to maintenance. Fleets will have better visibility into the entire repair process and will be able to make better-informed decisions about when and where they will service their vehicles.
The ultimate goal: Maximize planned maintenance and minimize unplanned breakdowns.
[ other head ] The growth and complexity of data
Bill Hathaway
Founder & CEO
Noregon Systems (www.Noregon.com) specializes in the creation of innovative diagnostic and vehicle data software solutions. Its JPRO branded commercial diagnostics system is a leading solution in the market, providing comprehensive in-shop and triage solutions for fleets, OES dealers, independent repair, municipalities and the military.
Over the next five to 10 years, the commercial vehicle industry will see a tremendous shift in how vehicle maintenance is managed. Advancements in vehicle technology, government regulations, pressures for better fuel economy, reduced dwell time and improved safety will be key industry drivers.
Leveraging the advancements in technology and making the best use of the available data will position companies to address and benefit from the changes affecting fleet maintenance.
One of the major keys for fleet maintenance is the ability to efficiently convert the increasing amounts of data from multiple sources into useful information. An area where the growth and complexity of data is readily apparent is the proliferation of electronic control units (ECU) on modern trucks.
The average number of ECUs on commercial trucks has risen from approximately 1.5 in 1995 to more than 11.5 in 2015. As a result, the amount of data being output by vehicles has grown exponentially. We anticipate the number of ECUs will continue to rise, resulting in more data being available to be transformed into valuable information.
ELD
Another impact will be the Federal Motor Carrier Safety Administration’s electronic logging device (ELD) mandate. Fleets will have until December 2017 to equip their vehicles with electronic devices capable of recording a driver’s hours of service.
While there is a strong focus on drivers, many fleets will use the newly required technology to expand their abilities to access richer, real-time vehicle data made available by the ECUs. Vehicle health and safety will be of key importance, especially as industry focus shifts towards the trend of autonomy.
From an industry perspective, the ELD mandate is expected to create explosive growth in telematics. This influx of connected trucks will generate considerable demand for data services within a telematics provider’s offering to translate raw vehicle data into actionable information.
TELEMATICS
Telematics services are beginning to offer fleets a real-time look into the status of all connected systems on their vehicles. They are able to see everything from major mechanical issues to a live look at fluid levels. This ability to gain access to a live, holistic view of vehicles is presenting fleets with a number of cost-saving benefits.
From a maintenance point of view, the ability to have insight into a truck’s status and location are a necessity for planning and delivering optimal maintenance. Fleets will be able to better route their vehicles to their preferred service centers, as well as plan for downtime and schedule additional vehicles when necessary.
The enhanced remote diagnostics available through telematics are eliminating a lot of the guess work from maintenance scheduling by providing precise information about all connected components on a vehicle while the vehicle is in transit.
CBM
Today, many vehicles are serviced on a fixed interval schedule, or when a maintenance need is easily identifiable. As the capabilities of enhanced remote diagnostics increase, fleets will begin implementing a condition-based maintenance (CBM) strategy that can optimize the frequency of maintenance activities.
Rather than scheduling maintenance based on miles or time-based intervals, fleets can send vehicles for maintenance on an as-needed basis. This is made possible by the information from remote diagnostic tools alerting to components failing or producing high-risk faults that could lead to potential breakdowns.
By implementing a CBM policy, fleets can reduce downtime and prolong the life of their vehicles by performing maintenance when necessary, rather than allowing minor issues to escalate into costly malfunctions.
For years, the potential savings of CBM was recognizable, but it has only recently started to become possible due to increased support from telematics services and the proper management of vehicle data.
PM
Building on the efficiencies of CBM, a stream of actionable information provided through telematics systems can enhance the practice of preventive maintenance (PM). By analyzing data from a satisfactory sample size of vehicles, data management companies can begin to detect trends, such as a minor faults escalating into major issues affecting multiple components if the vehicle is left unrepaired.
Recognizing which faults commonly escalate into serious issues that lead to malfunction can reduce repair costs through early detection and lower the number of unexpected breakdowns, benefiting driver satisfaction and load management. Using proven data trends to link particular faults with future failures streamlines the repair process by providing service centers with advanced notice of repair needs for better labor and inventory planning.
ANTICIPATED CHANGES
By effectively using enhanced remote diagnostics information, fleets will be able to better implement the anticipated technological changes of the future. When vehicle control is slowly removed from the human driver, systems must be in place to ensure the safety of all fleet assets, as well as the general public.
For example, remote monitoring can alert a driver if his platooning partner is likely to experience brake failure in the near future so correct adjustments can be made for both vehicles.
Maintenance requirements and possible inspection regulations of the new set of technologies likely to come will require additional electronic diagnosis and specialized training.
The explosion of data and deployment of new technologies will impact the workforce. Future top-level technicians will have a strong understanding of computing and software systems, as well as their traditional mechanical training.
Leveraging information with enhanced diagnostics, both for in-shop tools and remote monitoring services, could also help to ease the trend of technician shortages. The proper diagnosis and repair software will help ensure every technician on site is capable of fixing any problem the vehicle has.
Through educational and instructional material within the diagnostic software, entry-level technicians will be able to quickly increase their capabilities to confidently perform at a higher level.
As technologies continue to develop, fleet management will have to select the right platforms to truly benefit from the valuable information that will be made available. Using these services will increase fleet maintenance efficiencies and maximize vehicle uptime, resulting in a tremendous upside to business operations and the bottom line.
[ other head ] The ever-evolving truck
Homer Hogg
Manager, Technical Development
TA Truck Service (www.ta-petro.com/amenities/truck-repair-maintenance) has a [SVR3]
That network includes 242 truck service facilities, more than 1,000 repair bays and more than 3,000 technicians with ASE (National Institute for Automotive Service Excellence) and TIA (Tire Industry Association) certifications.
You don’t have to look very hard to see change on board the modern truck. From form to function, the industry standard vehicle is in a constant state of evolution.
Fuel optimization requirements alone have changed the appearance, and in some cases, the function of most tractors and trailers on the highway. Couple the required fuel use targets with stringent emissions regulations and you’ll find an ever-evolving truck, both outside and under the shell.
Truck manufacturers are scrambling to design and produce a vehicle that has little resistance from the tires to the windshield and molding, and these trends are dramatically impacting how and who performs maintenance on current and future trucks.
AFTERTREATMENT
Aftertreatment systems maintenance is quickly moving up the maintenance cost ladder for many trucking companies – both large and small. It is estimated that the current industry spend on aftertreatment systems is about $200 million – and it’s forecasted to climb to $2 billion by 2020.
This increase is staggering and serious. The main source of the increase is the diesel particulate filter (DPF), which must be serviced when it nears its capacity. Once that DPF light illuminates, or the truck reaches a preset mileage based on a company’s PM program, there are multiple options for service – a contributing factor to the increase.
Some prefer to have their filter liquid cleaned, some replace the filter, while others want their filter baked, pressured cleaned and reinstalled. Whatever the choice, downtime is required, meaning less productivity for the truck and the operator.
FUEL
Truck and engine manufacturers are also changing trucks to reach the rigorous fuel efficiency targets set by both the U.S. EPA and the market. Powertrain integration is trending, with engines and transmissions working through onboard electronic networks to optimize the amount of fuel needed to move the load at the desired speed. Automatic transmissions will continue to evolve and dominate the Class 8 truck market.
Couple these systems with smart cruise control software and suddenly we see the average fuel economy topping seven miles per gallon – and that number will climb exponentially over the next five plus years.
Another strategy to improve fuel economy is to get the engine to perform better at lower rpms. This is accomplished with sophisticated fuel mapping strategies and a fully integrated approach with the engine, transmission and drive axles.
Additionally, truck and engine manufacturers are looking for ways to remove weight from the truck. Evolving engine metals that reduce the weight, a shift in gear ratios in the rears and 6X2 axle configurations are just a few of the many enhancements that will continue to take hold of the North American truck market over the next several years.
More trucks are also coming off the assembly lines with tire monitoring and/or inflation systems. If the air pressure in a truck’s tires does not match the load on the vehicle according to the tire manufacturer’s guidelines, too much resistance will be the outcome, resulting in a loss of fuel efficiency. These new systems help prevent that loss.
ONBOARD TECHNOLOGIES
In order for truck manufacturers to effectively ensure these new trucks and onboard technologies are serviced properly and in a timely manner, we will see more remote monitoring and diagnostics of vehicles.
Most of the top truck makers in the U.S. have migrated to some sort of onboard telematics that transmit needed information to a call center or designated technical center. This allows for proactive analysis of the truck and truck systems, especially if the vehicle experiences a fault or potential fault that must be corrected.
A remote technician can analyze data or fault codes transmitted from the vehicle and apportion the vehicle to the nearest servicing facility as necessary. The name of the game is uptime, which is a premium in this competitive truck space.
TECHNICIAN SKILLS
If truck service organizations intend to be competitive working on this new equipment, their technicians’ skills must evolve. Some trucks roll off the assembly line with more than 40 computers on board. In fact, it will soon be difficult to locate an electrical device on a truck that is not computer controlled.
This means service technicians must develop their skills. They must be able to analyze the condition of multiplex signals, data bus quality and quickly decipher the root cause of communication errors and erratic computer inputs or outputs, regardless of what form the signals are in.
Once upon a time technicians commonly used a test light to check for voltage in a circuit. This practice is quickly disappearing. The modern technician needs information and must use a digital multimeter.
Some electronic circuits are very sensitive to test lights, which can allow too many amps to flow in these very tiny computer-controlled circuits that can only take milliamps or 1,000th of one amp.
ENGINE OIL
It is likely we will see zero weight oils over the next five years in order to meet the design of the modern engines.
Again, it is all about gaining fuel efficiencies. Horsepower is consumed in an engine by the engine itself trying to move the oil from place to place. Thinner oil is easier to move and reaches the top of the engine easier during cold starts.
If the zero weight oil is also a synthetic, then you have oil that is stronger and more consistently protects sensitive engine components.
Viscosity of oil is the oil’s resistance to flow. The more resistance oil has, the more energy the engine must use to move it.
Keep in mind that the first two numbers in an oil’s description is how the oil flows in cold temperatures, and the “W” stands for “Winter.” The last two numbers determine the oil’s viscosity at operating temperatures. The high torque, close tolerance engines will require engine oils to evolve over time.
Whether it’s adding miles per gallon or new technician expertise, one thing is for sure: Change in the fleet maintenance industry is eminent from the front bumper to the tail lights.
