Opportunistic maintenance policies for multi-machine production systems with quality and availability improvement

• Published in: Reliability engineering & system safety 2023-06, Vol.234, p.109183, Article 109183
• Main Authors: Shi, Haohao, Zhang, Ji, Zio, Enrico, Zhao, Xufeng
• Format: Article
• Language: English
• Subjects: Availability improvement; Business administration; Condition indicator; Engineering Sciences; Humanities and Social Sciences; Multi-machine production system; Opportunistic maintenance; Quality improvement
• ISSN: 0951-8320; 1879-0836
• DOI: 10.1016/j.ress.2023.109183

Effective maintenance policies can improve the production system performance by alleviating product quality degradation and increasing system reliability and availability. However, reliability, product quality degradation, and availability are conflicting optimization objectives and are rarely considered together in maintenance policy optimization. Aiming at optimizing these three objectives simultaneously, this paper proposes a joint model for opportunistic maintenance (OM), and product quality and availability improvement of a series multi-machine production system (MMPS). First, a condition index (CI) is developed to characterize the condition of individual machines based on monitoring data, and the corresponding threshold functions are developed to realize maintenance decision-making for individual machines. Then, considering maintenance dependence in the MMPS, based on the CI, the dual dynamic threshold functions are introduced: the preventive maintenance (PM) and the OM threshold functions, and a novel dual-dynamic-thresholds-based OM policy is developed. Whenever the CI of a machine reaches its PM threshold, all the other machines whose CI reaches the OM zone will be maintained together with this machine. Finally, a case study and comparisons are performed to show that the proposed model can simultaneously provide good production economic performance, high quality, and availability. •A joint model for a series multi-machine production system is developed.•A quantitative index is introduced to characterize the condition of the machines.•A hybrid performance factor is developed to evaluate the joint effect of maintenance.•Economic dependence and availability dependence are considered in the PM schedule.