Quality and reliability oriented maintenance for multistage manufacturing systems subject to condition monitoring

• Published in: Journal of manufacturing systems Vol. 52; pp. 76 - 85
• Main Authors: Lu, Biao, Zhou, Xiaojun
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.07.2019
• Subjects: Condition-based maintenance; Cost optimization; Importance measure; Multistage manufacturing system; Quality improvement; Importance measure; Multistage manufacturing system; Quality improvement; Cost optimization; Condition-based maintenance
• ISSN: 0278-6125; 1878-6642
• DOI: 10.1016/j.jmsy.2019.04.003

•The manufacturing system is subject to quality and reliability deteriorations.•Preventive maintenance (PM) is used to improve product quality and machine reliability.•The conditions of quality-related components are monitored to support PM decision-making.•A cost-based improvement factor is developed to select a group of machines for PM.•A quality and reliability assessment based PM-triggering decision rule is proposed. For manufacturing systems, product quality and machine reliability are two key health indicators, which usually deteriorate as a result of machine deterioration. Maintenance can mitigate the machine deterioration and consequently improve product quality and machine reliability. In this context, we propose a quality and reliability oriented condition-based maintenance (CBM) policy for the serial multistage manufacturing systems. In the policy, the conditions of quality-related components are monitored to evaluate the quality loss of final products and the system failure rate, which are further compared with the corresponding thresholds to decide whether to trigger preventive maintenance (PM). When PM is triggered, a cost-based improvement factor is introduced to identify the importance ranking of PM groups and then determine a group of machines for PM. This factor is developed based on importance measure and jointly considers the improvement of quality and reliability and the reduction of maintenance costs. A multi-level CBM decision-making process is developed to evaluate the total cost over the planning horizon for decision optimization. The effectiveness and superior performance of the proposed CBM policy is demonstrated through a case study of a serial four-stage machining system producing shaft sleeves.