Evaluation methodology for preventive maintenance in multi-state manufacturing systems considering different costs

ABSTRACT

In a multi-state manufacturing system, preventive maintenance is performed on other machines once the performance of a machine falls below a threshold state. Many investigations have been performed on the maintenance of manufacturing systems. However, studies on preventive maintenance for manufacturing systems that account for the different costs involved are limited. This paper focuses on the analysis of multi-state machines in a manufacturing system considering different costs. Subsequently, a cost-based preventive maintenance prioritisation method for multi-state machines is proposed. Based on the buffer capacity, three maintenance policies on the machines are discussed. Different machine failures lead to different maintenance priorities. The real-time buffer capacity greatly influences the selection of machines for preventive maintenance. The set of the optimal machines for preventive maintenance is determined based on the constraints of machine running time and different preventive maintenance costs. Finally, a numerical example is used to demonstrate the effectiveness of the proposed method.

KEYWORDS:

• Maintenance
• cost
• importance measure
• manufacturing systems
• reliability

Disclosure statement

No potential conflict of interest was reported by the author(s).

Data availability statement

The authors confirm that the data supporting the findings of this study are available within the article.

Additional information

Funding

The authors gratefully acknowledge the financial support for this research from the National Natural Science Foundation of China (Nos. 72071182, U1904211), the ministry of education's humanities and social sciences planning fund (No. 20YJA630012), the Key Science and Technology Program of Henan Province (No. 222102520019), the Program for Science & Technology Innovation Talents in Universities of Henan Province (No. 22HASTIT022), and the Program for young backbone teachers in Universities of Henan Province (No. 2021GGJS007).

Notes on contributors

Hongyan Dui

Hongyan Dui is a professor in School of Management, Zhengzhou University, China. He received his PhD from Northwestern Polytechnical University. His research focused on system reliability research, complex network optimisation, logistics and supply chain management and its reliability. His proposed integrated importance measure has been adopted by the JMP software of SAS system as one of the main mathematical tools for importance analysis of system.

Xingju Yang

Xingju Yang is currently pursuing the Master degree in management at Zhengzhou University. His research focuses on the system reliability and preventive maintenance modelling for multi-state systems.

Yining Fang

Yining Fang is a lecturer in National University of Defense Technology, China. She received her PhD from University of Alberta, Canada. Her research focuses on modelling and identification of complex systems.