IDEAS home Printed from https://ideas.repec.org/a/eee/reensy/v168y2017icp116-127.html

Opportunistic preventive maintenance scheduling for serial-parallel multistage manufacturing systems with multiple streams of deterioration

Author

Listed:
  • Lu, Biao
  • Zhou, Xiaojun

Abstract

This paper proposes a novel opportunistic preventive maintenance (PM) scheduling methodology for the serial-parallel multistage manufacturing systems (SP-MMSs), where PM is performed to improve both the reliability and product quality. A SP-MMS has two essential characteristics: (i) the products can go through different process routes; (ii) the deterioration of a machine will not only affect the key product characteristics (KPCs) formed at the current stage but also propagate to downstream stages and then affect the KPCs formed there. Consequently, the propagation of machine deterioration along different routes will generate multiple streams of deterioration. This phenomenon is mathematically modeled to evaluate the quality of final products. The PM scheduling is based on the modeling of total maintenance cost including minimal repair cost, quality loss and PM-related costs. Firstly, a tentative PM schedule is made for each individual machine by minimizing the corresponding total maintenance cost. Secondly, the tentative PM schedules of all machines are further adjusted to obtain the optimal PM schedule for the system by jointly considering the economic dependence and control of final product quality. A case study shows that the methodology can ensure reasonably high reliability and final product quality for the system with a low total maintenance cost.

Suggested Citation

  • Lu, Biao & Zhou, Xiaojun, 2017. "Opportunistic preventive maintenance scheduling for serial-parallel multistage manufacturing systems with multiple streams of deterioration," Reliability Engineering and System Safety, Elsevier, vol. 168(C), pages 116-127.
    • Handle: RePEc:eee:reensy:v:168:y:2017:i:c:p:116-127
    DOI: 10.1016/j.ress.2017.05.017
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0951832016308547
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.ress.2017.05.017?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to

    for a different version of it.

    References listed on IDEAS

    as
    1. Yin, Hui & Zhang, Guojun & Zhu, Haiping & Deng, Yuhao & He, Fei, 2015. "An integrated model of statistical process control and maintenance based on the delayed monitoring," Reliability Engineering and System Safety, Elsevier, vol. 133(C), pages 323-333.
    2. Robin P. Nicolai & Rommert Dekker, 2008. "Optimal Maintenance of Multi-component Systems: A Review," Springer Series in Reliability Engineering, in: Complex System Maintenance Handbook, chapter 11, pages 263-286, Springer.
    3. Panagiotidou, S. & Tagaras, G., 2012. "Optimal integrated process control and maintenance under general deterioration," Reliability Engineering and System Safety, Elsevier, vol. 104(C), pages 58-70.
    4. Do Van, Phuc & Barros, Anne & Bérenguer, Christophe & Bouvard, Keomany & Brissaud, Florent, 2013. "Dynamic grouping maintenance with time limited opportunities," Reliability Engineering and System Safety, Elsevier, vol. 120(C), pages 51-59.
    5. Pham, Hoang & Wang, Hongzhou, 1996. "Imperfect maintenance," European Journal of Operational Research, Elsevier, vol. 94(3), pages 425-438, November.
    6. Wang, Hongzhou, 2002. "A survey of maintenance policies of deteriorating systems," European Journal of Operational Research, Elsevier, vol. 139(3), pages 469-489, June.
    7. P J Vlok & J L Coetzee & D Banjevic & A K S Jardine & V Makis, 2002. "Optimal component replacement decisions using vibration monitoring and the proportional-hazards model," Journal of the Operational Research Society, Palgrave Macmillan;The OR Society, vol. 53(2), pages 193-202, February.
    8. Zhang, Xiaohong & Zeng, Jianchao, 2015. "A general modeling method for opportunistic maintenance modeling of multi-unit systems," Reliability Engineering and System Safety, Elsevier, vol. 140(C), pages 176-190.
    9. Rommert Dekker & Ralph Wildeman & Frank Duyn Schouten, 1997. "A review of multi-component maintenance models with economic dependence," Mathematical Methods of Operations Research, Springer;Gesellschaft für Operations Research (GOR);Nederlands Genootschap voor Besliskunde (NGB), vol. 45(3), pages 411-435, October.
    10. van Noortwijk, J.M., 2009. "A survey of the application of gamma processes in maintenance," Reliability Engineering and System Safety, Elsevier, vol. 94(1), pages 2-21.
    11. Das, K. & Lashkari, R.S. & Sengupta, S., 2007. "Machine reliability and preventive maintenance planning for cellular manufacturing systems," European Journal of Operational Research, Elsevier, vol. 183(1), pages 162-180, November.
    12. Ran Jin & Kaibo Liu, 2013. "Multimode variation modeling and process monitoring for serial-parallel multistage manufacturing processes," IISE Transactions, Taylor & Francis Journals, vol. 45(6), pages 617-629.
    13. Van Horenbeek, Adriaan & Pintelon, Liliane, 2013. "A dynamic predictive maintenance policy for complex multi-component systems," Reliability Engineering and System Safety, Elsevier, vol. 120(C), pages 39-50.
    14. Xia, Tangbin & Xi, Lifeng & Zhou, Xiaojun & Lee, Jay, 2012. "Dynamic maintenance decision-making for series–parallel manufacturing system based on MAM–MTW methodology," European Journal of Operational Research, Elsevier, vol. 221(1), pages 231-240.
    15. Bouvard, K. & Artus, S. & Bérenguer, C. & Cocquempot, V., 2011. "Condition-based dynamic maintenance operations planning & grouping. Application to commercial heavy vehicles," Reliability Engineering and System Safety, Elsevier, vol. 96(6), pages 601-610.
    16. Xiang, Yisha, 2013. "Joint optimization of X¯ control chart and preventive maintenance policies: A discrete-time Markov chain approach," European Journal of Operational Research, Elsevier, vol. 229(2), pages 382-390.
    17. Cho, Danny I. & Parlar, Mahmut, 1991. "A survey of maintenance models for multi-unit systems," European Journal of Operational Research, Elsevier, vol. 51(1), pages 1-23, March.
    18. Nguyen, Kim-Anh & Do, Phuc & Grall, Antoine, 2015. "Multi-level predictive maintenance for multi-component systems," Reliability Engineering and System Safety, Elsevier, vol. 144(C), pages 83-94.
    Full references (including those not matched with items on IDEAS)

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. de Jonge, Bram & Scarf, Philip A., 2020. "A review on maintenance optimization," European Journal of Operational Research, Elsevier, vol. 285(3), pages 805-824.
    2. Urbani, Michele & Brunelli, Matteo & Punkka, Antti, 2023. "An approach for bi-objective maintenance scheduling on a networked system with limited resources," European Journal of Operational Research, Elsevier, vol. 305(1), pages 101-113.
    3. Alaswad, Suzan & Xiang, Yisha, 2017. "A review on condition-based maintenance optimization models for stochastically deteriorating system," Reliability Engineering and System Safety, Elsevier, vol. 157(C), pages 54-63.
    4. Nguyen, Kim-Anh & Do, Phuc & Grall, Antoine, 2017. "Joint predictive maintenance and inventory strategy for multi-component systems using Birnbaum’s structural importance," Reliability Engineering and System Safety, Elsevier, vol. 168(C), pages 249-261.
    5. Nguyen, Kim-Anh & Do, Phuc & Grall, Antoine, 2015. "Multi-level predictive maintenance for multi-component systems," Reliability Engineering and System Safety, Elsevier, vol. 144(C), pages 83-94.
    6. Olde Keizer, Minou C.A. & Flapper, Simme Douwe P. & Teunter, Ruud H., 2017. "Condition-based maintenance policies for systems with multiple dependent components: A review," European Journal of Operational Research, Elsevier, vol. 261(2), pages 405-420.
    7. Vu, Hai Canh & Do, Phuc & Barros, Anne & Bérenguer, Christophe, 2014. "Maintenance grouping strategy for multi-component systems with dynamic contexts," Reliability Engineering and System Safety, Elsevier, vol. 132(C), pages 233-249.
    8. Vu, Hai Canh & Do, Phuc & Fouladirad, Mitra & Grall, Antoine, 2020. "Dynamic opportunistic maintenance planning for multi-component redundant systems with various types of opportunities," Reliability Engineering and System Safety, Elsevier, vol. 198(C).
    9. Jiawen Hu & Zuhua Jiang & Haitao Liao, 2017. "Preventive maintenance of a batch production system under time-varying operational condition," International Journal of Production Research, Taylor & Francis Journals, vol. 55(19), pages 5681-5705, October.
    10. Liu, Bin & Pandey, Mahesh D. & Wang, Xiaolin & Zhao, Xiujie, 2021. "A finite-horizon condition-based maintenance policy for a two-unit system with dependent degradation processes," European Journal of Operational Research, Elsevier, vol. 295(2), pages 705-717.
    11. Abu MD Ariful Islam & Jørn Vatn, 2023. "Condition-based multi-component maintenance decision support under degradation uncertainties," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 14(4), pages 961-979, December.
    12. Do, Phuc & Assaf, Roy & Scarf, Phil & Iung, Benoit, 2019. "Modelling and application of condition-based maintenance for a two-component system with stochastic and economic dependencies," Reliability Engineering and System Safety, Elsevier, vol. 182(C), pages 86-97.
    13. Liu, Gehui & Chen, Shaokuan & Ho, Tinkin & Ran, Xinchen & Mao, Baohua & Lan, Zhen, 2022. "Optimum opportunistic maintenance schedule over variable horizons considering multi-stage degradation and dynamic strategy," Reliability Engineering and System Safety, Elsevier, vol. 225(C).
    14. Do, Phuc & Vu, Hai Canh & Barros, Anne & Bérenguer, Christophe, 2015. "Maintenance grouping for multi-component systems with availability constraints and limited maintenance teams," Reliability Engineering and System Safety, Elsevier, vol. 142(C), pages 56-67.
    15. Olde Keizer, Minou C.A. & Teunter, Ruud H. & Veldman, Jasper, 2017. "Joint condition-based maintenance and inventory optimization for systems with multiple components," European Journal of Operational Research, Elsevier, vol. 257(1), pages 209-222.
    16. Andersen, Jesper Fink & Nielsen, Bo Friis, 2025. "A comparative study of time-based maintenance and condition-based maintenance for multi-component systems," Reliability Engineering and System Safety, Elsevier, vol. 256(C).
    17. de Jonge, Bram & Klingenberg, Warse & Teunter, Ruud & Tinga, Tiedo, 2016. "Reducing costs by clustering maintenance activities for multiple critical units," Reliability Engineering and System Safety, Elsevier, vol. 145(C), pages 93-103.
    18. Li, Heping & Deloux, Estelle & Dieulle, Laurence, 2016. "A condition-based maintenance policy for multi-component systems with Lévy copulas dependence," Reliability Engineering and System Safety, Elsevier, vol. 149(C), pages 44-55.
    19. Zhang, Xiaohong & Zeng, Jianchao, 2017. "Joint optimization of condition-based opportunistic maintenance and spare parts provisioning policy in multiunit systems," European Journal of Operational Research, Elsevier, vol. 262(2), pages 479-498.
    20. Olde Keizer, Minou C.A. & Teunter, Ruud H. & Veldman, Jasper, 2016. "Clustering condition-based maintenance for systems with redundancy and economic dependencies," European Journal of Operational Research, Elsevier, vol. 251(2), pages 531-540.

    More about this item

    Keywords

    ;
    ;
    ;
    ;
    ;

    Statistics

    Access and download statistics

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:reensy:v:168:y:2017:i:c:p:116-127. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: https://www.journals.elsevier.com/reliability-engineering-and-system-safety .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.