Predictive Maintenance and Upgrade Scheduling for Production Line under Multi-period Product-service Paradigm

Abstract

In the rapidly developing product–service paradigm, a multi-unit manufacturing system will be leased many times during life cycle. Besides maintenance programming for a single leasing period, an upgrade policy is essential to achieve life-cycle profit optimization during sequential periods. This article presents a framework integrating opportunistic maintenance scheduling and upgrade decision for the leased system throughout its life cycle based on a real-time prognostic method. With machine-level prognosis updating, system-level opportunistic predictive maintenance is dynamically achieved by leasing profit-saving calculations during each leasing period. Between successive leasing contracts, the optimal upgrade levels are dynamically determined through upgrade profit-saving maximization. A numerical example of a leased manufacturing line demonstrates the long-term economic effectiveness of this policy. The proposed framework extends traditional opportunistic maintenance policies in both the machine-level prognosis and the system-level upgrade decision. This framework can be applied to a broad range of leased systems with longer service lifetimes.

KEYWORDS:

• Opportunistic maintenance
• upgrade-level decision
• prognosis updating
• multi-unit leased system
• life-cycle management

Acknowledgements

This research is supported by the National Key Research and Development Program of China (2022YFF0605700), National Natural Science Foundation of China [51875359 and 71971139], Natural Science Foundation of Shanghai [20ZR1428600], Shanghai Science & Technology Innovation Center for System Engineering of Commercial Aircraft [FASE-2021-M7], Ministry of Education-China Mobile Joint Foundation Construction Project [MCM20180703], Oceanic Interdisciplinary Program of Shanghai Jiao Tong University [SL2021MS008] and CSSC-SJTU Marine Equipment Forward Looking Innovation Foundation [22B010432].

Disclosure statement

No potential conflict of interest was reported by the authors.

Data availability statement

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

Additional information

Funding

This research is supported by the National Key Research and Development Program of China (2022YFF0605700), National Natural Science Foundation of China [51875359 and 71971139], Natural Science Foundation of Shanghai [20ZR1428600], Shanghai Science & Technology Innovation Center for System Engineering of Commercial Aircraft [FASE-2021-M7], Ministry of Education-China Mobile Joint Foundation Construction Project [MCM20180703], Oceanic Interdisciplinary Program of Shanghai Jiao Tong University  [SL2021MS008] and CSSC-SJTU Marine Equipment Forward Looking Innovation Foundation [22B010432].