IDEAS home Printed from https://ideas.repec.org/a/eee/reensy/v228y2022ics0951832022004148.html
   My bibliography  Save this article

Integrated predictive maintenance approach for multistate manufacturing system considering geometric and non-geometric defects of products

Author

Listed:
  • Li, Yao
  • He, Yihai
  • Liao, Ruoyu
  • Zheng, Xin
  • Dai, Wei

Abstract

The adverse consequences caused by product defects can intuitively characterize the abnormal performance state of manufacturing systems in advance. Defects can be divided into geometric and non-geometric defects according to the difference of expression characteristics. Compared with machine failure data, the various effects and economic losses caused by product defects are more conducive to guide the development and optimization of maintenance strategies, which are rarely discussed. Therefore, from the perspective of product defect information, a novel integrated predictive maintenance (PdM) strategy is proposed to improve the performance of manufacturing systems. First, the influences of product geometric and non-geometric defects on the performance of manufacturing system are expounded, and two types of reliability metrics and the corresponding connotation are proposed and applied to PdM activities. Second, the mechanism of product defects caused by machine degradation is analyzed, and the quantitative models of the reliability are established. Third, the expected maintenance investment and economic loss in the planning horizon are evaluated, and the optimal PdM strategy is proposed according to the principle of total cost minimization. Finally, an industrial example of PdM decision making for a ferrite phase shifting unit manufacturing system is given to illustrate the effectiveness of the proposed approach.

Suggested Citation

  • Li, Yao & He, Yihai & Liao, Ruoyu & Zheng, Xin & Dai, Wei, 2022. "Integrated predictive maintenance approach for multistate manufacturing system considering geometric and non-geometric defects of products," Reliability Engineering and System Safety, Elsevier, vol. 228(C).
    • Handle: RePEc:eee:reensy:v:228:y:2022:i:c:s0951832022004148
    DOI: 10.1016/j.ress.2022.108793
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0951832022004148
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.ress.2022.108793?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 search for a different version of it.

    References listed on IDEAS

    as
    1. Safaei, Fatemeh & Taghipour, Sharareh, 2022. "Optimal preventive maintenance for repairable products with three types of failures sold under a renewable hybrid FRW/PRW policy," Reliability Engineering and System Safety, Elsevier, vol. 223(C).
    2. Wang, Wenzhuo & He, Yihai & Liao, Ruoyu & Cai, Yuqi & Zheng, Xin & Zhao, Yu, 2022. "Mission reliability driven functional healthy state modeling approach considering production rhythm and workpiece quality for manufacturing systems," Reliability Engineering and System Safety, Elsevier, vol. 226(C).
    3. Erkoyuncu, John Ahmet & Khan, Samir & Eiroa, Alexandre López & Butler, Nigel & Rushton, Keith & Brocklebank, Simon, 2017. "Perspectives on trading cost and availability for corrective maintenance at the equipment type level," Reliability Engineering and System Safety, Elsevier, vol. 168(C), pages 53-69.
    4. Han, Xiao & Wang, Zili & Xie, Min & He, Yihai & Li, Yao & Wang, Wenzhuo, 2021. "Remaining useful life prediction and predictive maintenance strategies for multi-state manufacturing systems considering functional dependence," Reliability Engineering and System Safety, Elsevier, vol. 210(C).
    5. Jin Xu & Hoang M. Tran & Natarajan Gautam & Satish T. S. Bukkapatnam, 2019. "Joint production and maintenance operations in smart custom-manufacturing systems," IISE Transactions, Taylor & Francis Journals, vol. 51(4), pages 406-421, April.
    6. Huynh, K.T., 2021. "An adaptive predictive maintenance model for repairable deteriorating systems using inverse Gaussian degradation process," Reliability Engineering and System Safety, Elsevier, vol. 213(C).
    7. Yihai He & Changchao Gu & Zhaoxiang Chen & Xiao Han, 2017. "Integrated predictive maintenance strategy for manufacturing systems by combining quality control and mission reliability analysis," International Journal of Production Research, Taylor & Francis Journals, vol. 55(19), pages 5841-5862, October.
    8. Yixiao Zhao & Yihai He & Di Zhou & Anqi Zhang & Xiao Han & Yao Li & Wenzhuo Wang, 2021. "Functional risk-oriented integrated preventive maintenance considering product quality loss for multistate manufacturing systems," International Journal of Production Research, Taylor & Francis Journals, vol. 59(4), pages 1003-1020, February.
    9. Xia, Tangbin & Dong, Yifan & Pan, Ershun & Zheng, Meimei & Wang, Hao & Xi, Lifeng, 2021. "Fleet-level opportunistic maintenance for large-scale wind farms integrating real-time prognostic updating," Renewable Energy, Elsevier, vol. 163(C), pages 1444-1454.
    10. Li, Yao & He, Yihai & Ai, Jun & Wang, Chengcheng & Han, Xiao & Liao, Ruoyu & Yang, Xiuzhen, 2022. "Functional health prognosis approach of multi-station manufacturing system considering coupling operational factors," Reliability Engineering and System Safety, Elsevier, vol. 219(C).
    11. He, Yihai & Zhao, Yixiao & Han, Xiao & Zhou, Di & Wang, Wenzhuo, 2020. "Functional risk-oriented health prognosis approach for intelligent manufacturing systems," Reliability Engineering and System Safety, Elsevier, vol. 203(C).
    12. Si, Guojin & Xia, Tangbin & Gebraeel, Nagi & Wang, Dong & Pan, Ershun & Xi, Lifeng, 2022. "A reliability-and-cost-based framework to optimize maintenance planning and diverse-skilled technician routing for geographically distributed systems," Reliability Engineering and System Safety, Elsevier, vol. 226(C).
    13. Xia, Tangbin & Si, Guojin & Shi, Guo & Zhang, Kaigan & Xi, Lifeng, 2022. "Optimal selective maintenance scheduling for series–parallel systems based on energy efficiency optimization," Applied Energy, Elsevier, vol. 314(C).
    14. Cai, Baoping & Zhang, Yanping & Wang, Haifeng & Liu, Yonghong & Ji, Renjie & Gao, Chuntan & Kong, Xiangdi & Liu, Jing, 2021. "Resilience evaluation methodology of engineering systems with dynamic-Bayesian-network-based degradation and maintenance," Reliability Engineering and System Safety, Elsevier, vol. 209(C).
    15. Cheng, Guo Qing & Zhou, Bing Hai & Li, Ling, 2018. "Integrated production, quality control and condition-based maintenance for imperfect production systems," Reliability Engineering and System Safety, Elsevier, vol. 175(C), pages 251-264.
    16. Wang, Xiaoyue & Zhao, Xian & Wang, Siqi & Sun, Leping, 2020. "Reliability and maintenance for performance-balanced systems operating in a shock environment," Reliability Engineering and System Safety, Elsevier, vol. 195(C).
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Liao, Ruoyu & He, Yihai & Feng, Tianyu & Yang, Xiuzhen & Dai, Wei & Zhang, Weifang, 2023. "Mission reliability-driven risk-based predictive maintenance approach of multistate manufacturing system," Reliability Engineering and System Safety, Elsevier, vol. 236(C).
    2. Shi, Haohao & Zhang, Ji & Zio, Enrico & Zhao, Xufeng, 2023. "Opportunistic maintenance policies for multi-machine production systems with quality and availability improvement," Reliability Engineering and System Safety, Elsevier, vol. 234(C).
    3. Yao, Jinyong & Gao, Zhanfei & He, Yihai & Peng, Chong, 2024. "Integrated mission reliability modeling for multistate manufacturing systems considering heterogeneous feedstocks based on extended stochastic flow manufacturing network," Reliability Engineering and System Safety, Elsevier, vol. 243(C).
    4. Yang, Xiuzhen & He, Yihai & Liao, Ruoyu & Cai, Yuqi & Dai, Wei, 2024. "Mission reliability-centered opportunistic maintenance approach for multistate manufacturing systems," Reliability Engineering and System Safety, Elsevier, vol. 241(C).

    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. Yang, Xiuzhen & He, Yihai & Liao, Ruoyu & Cai, Yuqi & Ai, Jun, 2022. "Integrated mission reliability modeling based on extended quality state task network for intelligent multistate manufacturing systems," Reliability Engineering and System Safety, Elsevier, vol. 223(C).
    2. Liao, Ruoyu & He, Yihai & Zhang, Jishan & Zheng, Xin & Zhang, Anqi & Zhang, Weifang, 2023. "Reliability proactive control approach based on product key reliability characteristics in manufacturing process," Reliability Engineering and System Safety, Elsevier, vol. 237(C).
    3. Ye, Zhenggeng & Cai, Zhiqiang & Yang, Hui & Si, Shubin & Zhou, Fuli, 2023. "Joint optimization of maintenance and quality inspection for manufacturing networks based on deep reinforcement learning," Reliability Engineering and System Safety, Elsevier, vol. 236(C).
    4. Yang, Xiuzhen & He, Yihai & Liao, Ruoyu & Cai, Yuqi & Dai, Wei, 2024. "Mission reliability-centered opportunistic maintenance approach for multistate manufacturing systems," Reliability Engineering and System Safety, Elsevier, vol. 241(C).
    5. Li, Yao & He, Yihai & Ai, Jun & Wang, Chengcheng & Han, Xiao & Liao, Ruoyu & Yang, Xiuzhen, 2022. "Functional health prognosis approach of multi-station manufacturing system considering coupling operational factors," Reliability Engineering and System Safety, Elsevier, vol. 219(C).
    6. Zhao, Xian & He, Zongda & Wu, Yaguang & Qiu, Qingan, 2022. "Joint optimization of condition-based performance control and maintenance policies for mission-critical systems," Reliability Engineering and System Safety, Elsevier, vol. 226(C).
    7. Azimpoor, Samareh & Taghipour, Sharareh, 2021. "Joint inspection and product quality optimization for a system with delayed failure," Reliability Engineering and System Safety, Elsevier, vol. 215(C).
    8. Cheng, Guoqing & Li, Ling, 2020. "Joint optimization of production, quality control and maintenance for serial-parallel multistage production systems," Reliability Engineering and System Safety, Elsevier, vol. 204(C).
    9. Pinciroli, Luca & Baraldi, Piero & Zio, Enrico, 2023. "Maintenance optimization in industry 4.0," Reliability Engineering and System Safety, Elsevier, vol. 234(C).
    10. Liao, Ruoyu & He, Yihai & Feng, Tianyu & Yang, Xiuzhen & Dai, Wei & Zhang, Weifang, 2023. "Mission reliability-driven risk-based predictive maintenance approach of multistate manufacturing system," Reliability Engineering and System Safety, Elsevier, vol. 236(C).
    11. Wang, Wenzhuo & He, Yihai & Liao, Ruoyu & Cai, Yuqi & Zheng, Xin & Zhao, Yu, 2022. "Mission reliability driven functional healthy state modeling approach considering production rhythm and workpiece quality for manufacturing systems," Reliability Engineering and System Safety, Elsevier, vol. 226(C).
    12. Vrignat, Pascal & Kratz, Frédéric & Avila, Manuel, 2022. "Sustainable manufacturing, maintenance policies, prognostics and health management: A literature review," Reliability Engineering and System Safety, Elsevier, vol. 218(PA).
    13. Wang, Lin & Lu, Zhiqiang & Ren, Yifei, 2020. "Joint production control and maintenance policy for a serial system with quality deterioration and stochastic demand," Reliability Engineering and System Safety, Elsevier, vol. 199(C).
    14. Li, Xin & Zhong, Xiang & Shao, Haidong & Han, Te & Shen, Changqing, 2021. "Multi-sensor gearbox fault diagnosis by using feature-fusion covariance matrix and multi-Riemannian kernel ridge regression," Reliability Engineering and System Safety, Elsevier, vol. 216(C).
    15. Chen, Zhaoxiang & Chen, Zhen & Zhou, Di & Pan, Ershun, 2023. "Energy-oriented opportunistic maintenance optimization of continuous process manufacturing systems with two types of stochastic durations," Reliability Engineering and System Safety, Elsevier, vol. 237(C).
    16. Patrick Zschech & Kai Heinrich & Raphael Bink & Janis S. Neufeld, 2019. "Prognostic Model Development with Missing Labels," Business & Information Systems Engineering: The International Journal of WIRTSCHAFTSINFORMATIK, Springer;Gesellschaft für Informatik e.V. (GI), vol. 61(3), pages 327-343, June.
    17. Jiang, Deyin & Chen, Tianyu & Xie, Juanzhang & Cui, Weimin & Song, Bifeng, 2023. "A mechanical system reliability degradation analysis and remaining life estimation method——With the example of an aircraft hatch lock mechanism," Reliability Engineering and System Safety, Elsevier, vol. 230(C).
    18. Yang, Bofan & Zhang, Lin & Zhang, Bo & Xiang, Yang & An, Lei & Wang, Wenfeng, 2022. "Complex equipment system resilience: Composition, measurement and element analysis," Reliability Engineering and System Safety, Elsevier, vol. 228(C).
    19. Liang, Zhenglin & Li, Yan-Fu, 2023. "Holistic Resilience and Reliability Measures for Cellular Telecommunication Networks," Reliability Engineering and System Safety, Elsevier, vol. 237(C).
    20. Lin Wang & Zhiqiang Lu & Yifei Ren, 2019. "A rolling horizon approach for production planning and condition-based maintenance under uncertain demand," Journal of Risk and Reliability, , vol. 233(6), pages 1014-1028, December.

    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:228:y:2022:i:c:s0951832022004148. 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.