Abstract
An optimal preventive maintenance policy and optimization method of operation parameters for a production line consisting of multiple execution units is described herein. According to the characteristics of the production unit, the relationship between the reliability and operating parameters of the execution unit is established, as well as its relationship between the operating parameters and maintenance cost. The minimum maintenance cost and effective operating speed is selected as the objective, and the optimal parameters are derived by heuristic algorithm. Finally, a numerical example and simulation experiments are shown which validated the effectiveness of the proposed method.
Similar content being viewed by others
Abbreviations
- \( U_{i} \) :
-
The execution unit (where \( i = 1, \ldots , n \))
- \( {\text{A}} \) :
-
Minor repair
- \( {\text{B}} \) :
-
Preventive maintenance
- C :
-
Replacement
- \( T_{MA} \) :
-
The repair time of minor repair
- \( T_{MB} \) :
-
The repair time of preventive maintenance
- \( T_{MC} \) :
-
The repair time of replacement
- \( T_{order} \) :
-
The order cycle
- \( T_{j} \) :
-
Maintenance cycle (where \( j = 1, \ldots , m \))
- \( T_{P\left( j \right)} \) :
-
The working period (where \( j = 1, \ldots , m \))
- \( T_{M\left( j \right)} \) :
-
The maintenance period (where \( j = 1, \ldots , m \))
- \( R\left( t \right) \) :
-
The system reliability
- \( R_{{\left( {i,j + 1} \right)}}^{ + } \) :
-
The system reliability of the initial value (where \( i = 1, \ldots , n \), \( j = 1, \ldots , m \))
- \( N_{A} \) :
-
The number of minor repair
- \( N_{B} \) :
-
The number of preventive maintenance
- \( N_{C} \) :
-
The number of replacement
- \( N_{R} \) :
-
The execution unit is replaced by new one when \( N_{B} \) is reached \( N_{R} \)
- \( R_{B} \) :
-
The reliability threshold for the execution unit to be moved to have preventive maintenance
- \( v \) :
-
The operating speed of the execution unit
- \( \theta \) :
-
The age-return factor
- \( ME_{i} \) :
-
The maintenance cost of the execution unit \( U_{i} \)
- \( ME \) :
-
The maintenance cost of the production line
- \( V_{R} \) :
-
The effective speed of the production line
- \( W_{i} \left( t \right) \) :
-
The wear and tear amount of the execution unit \( U_{i} \)
- \( u \) :
-
The wear and tear amount rate of the executive unit \( U_{i} \)
- \( k_{i} \) :
-
The factor of wear amount
- \( p \) :
-
The pressure in the unit area of the friction surface
- \( v_{l} \) :
-
The relative sliding speed of the friction surface
- \( \alpha \) :
-
The factor of friction
- \( \beta \) :
-
The factor of speed factor
- \( l \) :
-
The relative sliding distance
- \( t_{l} \) :
-
The time for the component to operating once
- \( \overline{p} \) :
-
The mean of \( p \)
- \( s_{p} \) :
-
The standard deviation of \( p \)
- \( \overline{v} \) :
-
The mean of \( v \)
- \( s_{v} \) :
-
The standard deviation of \( v \)
- \( \overline{{W_{i} \left( t \right)}} \) :
-
The mean of the wear and tear amount
- \( S_{W} \) :
-
The standard deviation of the wear and tear amount
- \( W_{max} \) :
-
The maximum allowable the wear and tear amount
- \( {{\upsigma }} \) :
-
The standard deviation
- \( M_{A} \) :
-
The cost of a minor repair
- \( M_{B} \) :
-
The cost of preventive maintenance
- \( M_{C} \) :
-
The cost of replacement
- \( M_{D} \) :
-
The downtime loss for a single maintenance
- \( G\left( t \right) \) :
-
The total optimization objective function
References
Ali, I., Raghav, Y. S., Khan, F. M., & Bari, A. (2013). Selective maintenance in system reliability with random costs of repairing and replacing the components. Communications in Statistics-Simulation and Computation, 42(9), 2026–2039.
Belyi, D., Popova, E., Morton, D. P., & Damien, P. (2017). Bayesian failure-rate modeling and preventive maintenance optimization. European Journal of Operational Research, 262(3), 1085–1093.
Chen, H. C. (2013). Optimum capacity determination of stand-alone hybrid generation system considering cost and reliability. Applied Energy, 103(1), 155–164.
Fitouhi, M. C., & Nourelfath, M. (2014). Integrating noncyclical preventive maintenance scheduling and production planning for multi-state systems. Reliability Engineering and System Safety, 121(1), 175–186.
Gustavsson, E., Patriksson, M., Strömberg, A. B., Wojciechowski, A., & Wojciechowski, A. (2014). Preventive maintenance scheduling of multi-component systems with interval costs. Computers and Industrial Engineering, 76(C), 390–400.
Hong, H. P., Zhou, W., Zhang, S., & Ye, W. (2014). Optimal condition-based maintenance decisions for systems with dependent stochastic degradation of components. Reliability Engineering and System Safety, 121(1), 276–288.
Hou, W. R., & Jiang, Z. H. (2013). An opportunistic maintenance policy of multi-unit series production system with consideration of imperfect maintenance. Applied Mathematics and Information Sciences, 7(1L), 283–290.
Khatab, A., Aghezzaf, E. H., Diallo, C., & Djelloul, I. (2018). Selective maintenance optimisation for series-parallel systems alternating missions and scheduled breaks with stochastic durations. International Journal of Production Research, 55(10), 3008–3024.
Lee, J. H., Li, J., & Horst, J. A. (2017). Serial production lines with waiting time limits: Bernoulli reliability model. IEEE Transactions on Engineering Management, 65(2), 316–329.
Lin, J., Pulido, J., & Asplund, M. (2015). Reliability analysis for preventive maintenance based on classical and bayesian semi-parametric degradation approaches using locomotive wheel-sets as a case study. Reliability Engineering and System Safety, 134, 143–156.
Liu, Y., Chen, Y. M., & Jiang, T. (2018). On sequence planning for selective maintenance of multi-state systems under stochastic maintenance durations. European Journal of Operational Research, 268, 113–127.
Liu, Y., Huang, H. Z., Wang, Z., Li, Y., & Yang, Y. (2013). A joint redundancy and imperfect maintenance strategy optimization for multi-state systems. IEEE Transactions on Reliability, 62(2), 368–378.
Lu, B., & Zhou, X. J. (2017). Opportunistic preventive maintenance scheduling for serial-parallel multistage manufacturing systems with multiple streams of deterioration. Reliability Engineering and System Safety, 168, 116–127.
Moghaddam, K. S. (2015). Preventive maintenance and replacement optimization on cnc machine using multiobjective evolutionary algorithms. International Journal of Advanced Manufacturing Technology, 76(9–12), 2131–2146.
Mokhtar, E. H. A., Laggoune, R., & Chateauneuf, A. (2016). Imperfect preventive maintenance policy for complex systems based on bayesian networks. Quality and Reliability Engineering International, 33(4), 751–765.
Nahas, N., & Nourelfath, M. (2017). Joint optimization of maintenance, buffers and machines in manufacturing lines. Engineering Optimization, 50(1), 1–18.
Rahmati, S. H. A., Ahmadi, A., & Karimi, B. (2018). Multi-objective evolutionary simulation based optimization mechanism for a novel stochastic reliability centered maintenance problem. Swarm and Evolutionary Computation, 40(2018), 255–271.
Rashidnejad, M., Ebrahimnejad, S., & Safari, J. (2018). A bi-objective model of preventive maintenance planning in distributed systems considering vehicle routing problem. Computers and Industrial Engineering, 120(2018), 360–381.
Seidgar, H., Zandieh, M., & Mahdavi, I. (2016). Bi-objective optimization for integrating production and preventive maintenance scheduling in two-stage assembly flow shop problem. Journal of the Chinese Institute of Industrial Engineers, 33(6), 404–425.
Shi, H., & Zeng, J. C. (2016). Real-time prediction of remaining useful life and preventive opportunistic maintenance strategy for multi-component systems considering stochastic dependence. Computers and Industrial Engineering, 93, 192–204.
Taleb, S., & Aissani, A. (2016). Preventive maintenance in an unreliable m/g/1 retrial queue with persistent and impatient customers. Annals of Operations Research, 247(1), 291–317.
Wang, Y. N., Ning, B. G., & Yin, M. A. (2018). Integrated optimization of production plan and preventive maintenance plan for multi-state system. Machinery and Electronics, 36(2), 39–50.
Xiao, L., Song, S. L., Chen, X. H., & Coit, D. W. (2016). Joint optimization of production scheduling and machine group preventive maintenance. Reliability Engineering and System Safety, 146, 68–78.
Yang, J., & Luo, W. C. (2018). On rescheduling for two-machine flow shop system with the arrival of new jobs. American Journal of Mathematical and Management Sciences, 37(3), 262–271.
Zandieh, M., Joreir-Ahmadi, M. N., & Fadaei-Rafsanjani, A. (2017). Buffer allocation problem and preventive maintenance planning in non-homogenous unreliable production lines. International Journal of Advanced Manufacturing Technology, 91(5), 1–13.
Zhou, X. J., Huang, K. M., Xi, L. F., & Lee, J. (2015). Preventive maintenance modeling for multi-component systems with considering stochastic failures and disassembly sequence. Reliability Engineering and System Safety, 142, 231–237.
Acknowledgements
This work was supported by the National Natural Science Foundation of China (71271156) and the Natural Science Foundation of Zhejiang Province (LY19G010007).
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Zhou, H., Wang, S., Qi, F. et al. Maintenance modeling and operation parameters optimization for complex production line under reliability constraints. Ann Oper Res 311, 507–523 (2022). https://doi.org/10.1007/s10479-019-03228-9
Published:
Issue Date:
DOI: https://doi.org/10.1007/s10479-019-03228-9