An integrated model of statistical process control and maintenance planning for a two-stage dependent process under general deterioration

Consider a two-stage dependent process in which each stage has a unique quality characteristic. Based on a regression formula, the quality characteristic of the second stage is dependent on that of the first stage. There may be two assignable causes in the process. Each cause can lead to a change in the mean of the process. The process failure mechanism for each stage follows a general continuous distribution function, and two control charts are simultaneously used to monitor the process. Specifically, the first stage is monitored using a Shwehart control chart, and the second stage is monitored using a cause-selecting control chart. An integrated model is developed for maintenance planning (MP) and statistical process control (SPC). To analyse the performance of the integrated model, a stand-alone model for SPC is developed. A comparison of the two models, i.e., the integrated model and the stand-alone model, is conducted. Finally, using a fractional factorial design, a depth analysis is performed about the integrated model. [Received: 10 February 2018; Revised: 21 April 2018; Revised: 4 June 2018; Revised: 12 September 2018; Revised: 7 October 2018; Accepted: 9 October 2018]