Optimizing an integrated production and quality strategy considering inspection and preventive maintenance errors

Preventive maintenance (PM) can slow the deterioration process of a repairable system and restore the system to a younger state. The proposed PM model of this paper focuses on the restoration effect of degradation rate reduction which can only relieve stress temporarily and slow the rate of system degradation while the hazard rate is still monotonically increased. This PM model considers a deteriorating but repairable system (or equipment) with a finite life time period. This PM model is modified based on an original degradation-rate-reduction PM model over a finite time span of which the searching range for the optimal solution of the time interval between each PM is limited. It is demonstrated that the proposed degradation-rate-reduction PM model over a finite time period can have a better optimal solution than the original PM model. The algorithm of finding the optimal solution for the modified PM model is developed. Examples are provided and are compared with the corresponding original PM model.

Purpose Making decisions on preventive maintenance (PM) policy and buffer sizing, as is often studied, may not result in overall optimization. The purpose of this paper is to propose a joint model that integrates PM and buffer sizing with consideration of quality loss for a degenerating system, which aims to minimize the average operation cost for a finite horizon. The opportunistic maintenance (OM) policy which could increase the output and decrease the cost of the system is also explored. Design/methodology/approach A joint PM and buffer size model considering quality loss is proposed. In this model, the time-based PM and the condition-based PM are taken on the upstream and the downstream machine, respectively. Further, the OM policy based on the theory of constraints (TOC) is also considered. An iterative search algorithm with Monte Carlo is developed to solve the non-linear model. A case study is conducted to illustrate the performance of the proposed PM policies. Findings The superiority of the proposed integrated policies compared with the separate PM policy is demonstrated. Effects of the policies are testified. The advantages of the proposed TOC-based OM policy is highlighted in terms of low-cost and high-output. Originality/value Few studies have been carried out to integrate decisions on PM and buffer size when taking the quality loss into consideration for degenerating systems. Most PM models treat machines equally ignoring the various roles of them. A more comprehensive and integrated model based on TOC is proposed, accompanied by an iterative search algorithm with Monte Carlo for solving it. An OM policy to further improve the performance of system is also presented.

Preventive maintenance (PM) is a maintenance program with activities initiated at predetermined intervals, or according to prescribed criteria, and intended to reduce the probability of failure, or the degradation of the functioning of an item. In the literature, a number of PM models have been introduced to depict the effectiveness of PM. Based on these models, approaches to scheduling PM policies have been considerably studied. This paper attempts to review existing PM models, and investigate their inter-relationships. We then categorize these models into three classes: linear, nonlinear, and a hybrid of both. These three PM model classes depict the relationships of the hazard functions before, and after a PM. Possible extensions to these three PM models are discussed. The statistical properties for models are derived, and approaches to optimizing the PM policy are given.

Stress-reducing preventive maintenance model for a unit under stressful environment

This paper proposes an integrated preventive maintenance and economic production quantity model. A condition-based maintenance policy is described by a random coefficient regression model, based on which the monitored condition is divided into two parts: the actual condition and random error. Products are produced in batches and the system is monitored at the end of each batch. If the observed system condition either reaches or exceeds the critical level, the system should be renewed by preventive maintenance. However, if the actual system condition reaches the failure level during the production process, the system fails and should be renewed immediately. Based on these two renewal situations, we construct a model of expected cost per unit time using the renewal reward theory. The critical level and production lot size are decision variables, which can be obtained by minimizing the cost model. We also develop a simulation process to obtain the optimal results in another way and validate our proposed cost model. Finally, a real case study is given to demonstrate the model and the simulation process.

This paper considers replacement and maintenance policies for an operating unit which works at random times for jobs. The unit undergoes minimal repairs at failures and is replaced at a planned time T or at a number N of working times, whichever occurs first. The expected cost rate is obtained, and an optimal policy which minimizes it is derived analytically. The imperfect preventive maintenance (PM) model, where the unit is improved by PM after the completion of each working time, is analyzed. Furthermore, when the work of a job incurs some damage to the unit, the replacement model with number N is proposed. The expected cost rate is obtained by using theory of cumulative processes. Two modified models, where the unit is replaced at number N or at the first completion of the working time over time T, and it is replaced at T or number N, whichever occurs last, are also proposed. Finally, when the unit is replaced at time T, number N or Kth failure, whichever occurs first, the expected cost rate is also obtained.

We discuss models of preventive maintenance (PM) under different assumptions on the failure/repair processes. The main emphasis is on the PM modeling under the Brown‐Proschan model for minimal/perfect repairs. We also present the generalization of this model for the failure/repair process governed by the generalized Polya process. Some comparisons with conventional PM models are discussed (Nonhomogeneous Poisson process, renewal process, and geometric process of failure/repairs). Several practical examples are considered.

Among the different maintenance techniques applied to wind turbine (WT) components, online condition monitoring is probably the most promising technique. The maintenance models based on online condition monitoring have been examined in many studies. However, no study has considered preventive maintenance models with incorporated probabilities of correct and incorrect decisions made during continuous condition monitoring. This article presents a mathematical model of preventive maintenance, with imperfect continuous condition monitoring of the WT components. For the first time, the article introduces generalized expressions for calculating the interval probabilities of false positive, true positive, false negative, and true negative when continuously monitoring the condition of a WT component. Mathematical equations that allow for calculating the expected cost of maintenance per unit of time and the average lifetime maintenance cost are derived for an arbitrary distribution of time to degradation failure. A numerical example of WT blades maintenance illustrates that preventive maintenance with online condition monitoring reduces the average lifetime maintenance cost by 11.8 times, as compared to corrective maintenance, and by at least 4.2 and 2.6 times, compared with predetermined preventive maintenance for low and high crack initiation rates, respectively.

Most preventive maintenance (PM) models require, as inputs, information on the behaviour of the equipment under failure-only maintenance (FM). Once a schedule of PM has been applied, data arising from failures are affected by the PM. Over life the behaviour that would occur under FM changes. But PM also tends to delay aging processes. This paper examines: 1) how data collected under four kinds of PM policy can be modified to re-assess the FM characteristics, and 2) how to tell whether an apparent change in them is important. The approach takes account of engineering as well as statistical factors. It concludes that: 1. Estimation of distributions and costs as they would be under FM from data collected under PM cannot be accurate but a suboptimal policy can be worse. 2. A different type of PM policy might be required following changes to costs and/or distribution. The optimum under one model might not be the overall optimum. 3. The solutions suggested in the paper remain unproved due to the ``data problem''. Mathematical research alone can never produce workable procedures. A viable methodology will need years of experimentation with real systems. 4. The potential savings are huge.

An Efficient Jaya Algorithm for Joint Optimization of Preventive Maintenance and Quality Policy in Production Systems

This chapter deals with a preventive maintenance problem for consecutive-k-out-of-n and connected-(r, s)-out-of-(m, n): F systems. The system failure probability of two types of multi-unit systems is analytically derived by utilizing the system failure paths. Dependence mechanisms between components in the systems are illustrated and the system failure paths under dependence models are shown. The expected cost rates of corrective maintenance, age preventive maintenance, and condition-based maintenance policies are estimated. The optimal maintenance policies to minimize the expected cost rates in two preventive maintenance models are obtained and three maintenance policies are compared by numerical examples.

Optimal rearrangement and preventive maintenance policies for heterogeneous balanced systems with three failure modes

This article has been retracted. A retraction notice can be found at https://doi.org/10.3233/JIFS-219433.

Dynamic dispatching and preventive maintenance for parallel machines with dispatching-dependent deterioration

Different type of maintenance problems have been investigated during the past decades. With the growth in complexity of modern systems, the cost of purchasing new systems becomes higher ever than before. Surprisingly, very little attention in the literature has been paid to the failure replacement in these preventive maintenance models. However, in practice most systems incur increasingly expensive down time costs when the systems suffer the unexpected failures. The major changes to the standard maintenance model in this research are the addition of a failure replacement cost for a failed system and the reliability limit for which system has to be replaced. The overall objective of this research is to propose an efficient algorithm to obtain the optimal maintenance policy. The optimal preventive maintenance policy is investigated with incorporating the costs of minimal repair, imperfect preventive maintenance, failure replacement and preventive replacement. The specific maintenance actions for a repairable system are when to perform an imperfect preventive maintenance or to replace the system while the system is in the operating condition. In another case, the specific maintenance actions for a repairable system are whether to replace the system, or to perform a minimal repair when the system fails. The number of imperfect preventive maintenance and the control limits of the optimal maintenance policy are calculated under the expected average cost rate criterion.