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Remaining useful life prediction and preventive maintenance approach for multistate manufacturing systems with feedstock heterogeneity

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  • Gao, Zhanfei
  • Yao, Jinyong
  • He, Yihai
  • Dui, Hongyan
  • Liang, Zhaolei
  • Li, Jiao

Abstract

The heterogeneity of feedstock quality can interfere with the performance deterioration of processing machines, which disturbs the reliability degradation of manufacturing systems. Therefore, system reliability modeling considering feedstock heterogeneity is crucial for remaining useful life (RUL) prediction and preventive maintenance of manufacturing systems. According to the RUL prediction model of manufacturing systems considering feedstock heterogeneity, this study proposes a profit-based importance measure evaluation model and utilizes it as a guide for preventive maintenance decision. The proposed method mainly includes the following steps: (1) analyzing the degradation mechanism of manufacturing systems with feedstock heterogeneity and expounding the reliability and RUL connotation of manufacturing systems, (2) proposing a RUL prediction approach for manufacturing systems based on system reliability model considering feedstock heterogeneity, (3) developing a profit-based importance measure model to evaluate the contribution of a machine’s maintenance action to the profit that the system can increase over its RUL, thus determining the maintenance priority of processing machines and optimizing preventive maintenance strategy. The effectiveness and superior performance of proposed approach is verified through an industrial case study of a servo valve spool manufacturing system.

Suggested Citation

  • Gao, Zhanfei & Yao, Jinyong & He, Yihai & Dui, Hongyan & Liang, Zhaolei & Li, Jiao, 2025. "Remaining useful life prediction and preventive maintenance approach for multistate manufacturing systems with feedstock heterogeneity," Reliability Engineering and System Safety, Elsevier, vol. 264(PA).
    • Handle: RePEc:eee:reensy:v:264:y:2025:i:pa:s0951832025005538
    DOI: 10.1016/j.ress.2025.111352
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