Skip to main content
Log in

A review of condition-based maintenance: Its prognostic and operational aspects

  • Review Article
  • Published:
Frontiers of Engineering Management Aims and scope Submit manuscript

Abstract

Condition-based maintenance (CBM) detects early signs of failure and dictates when maintenance should be performed based on the actual condition of a system. In this paper, we first review some of the recent research on CBM under various physical structures and signal data. Then, we summarize several kinds of prognostic models that use monitoring information to estimate the reliability of complex systems or products. Monitoring information also facilitates operational decisions in production planning, spare parts management, reliability improvement, and prognostics and health management. Finally, we suggest some research opportunities for the reliability and operations management communities to fill the research gap between these two fields.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Similar content being viewed by others

References

  • Aizpurua J I, Catterson V M, Papadopoulos Y, Chiacchio F, D’Urso D (2017). Supporting group maintenance through prognostics-enhanced dynamic dependability prediction. Reliability Engineering & System Safety, 168: 171–188

    Google Scholar 

  • Alaswad S, Xiang Y (2017). A review on condition-based maintenance optimization models for stochastically deteriorating system. Reliability Engineering & System Safety, 157: 54–63

    Google Scholar 

  • Armstrong M J, Atkins D R (1996). Joint optimization of maintenance and inventory policies for a simple system. IIE Transactions, 28(5): 415–424

    Google Scholar 

  • Aronis K P, Magou I, Dekker R, Tagaras G (2004). Inventory control of spare parts using a Bayesian approach: A case study. European Journal of Operational Research, 154(3): 730–739

    MATH  Google Scholar 

  • Attardi L, Guida M, Pulcini G (2005). A mixed-Weibull regression model for the analysis of automotive warranty data. Reliability Engineering & System Safety, 87(2): 265–273

    Google Scholar 

  • Bae S J, Mun B M, Chang W, Vidakovic B (2019). Condition monitoring of a steam turbine generator using wavelet spectrum based control chart. Reliability Engineering & System Safety, 184: 13–20

    Google Scholar 

  • Bahria N, Chelbi A, Bouchriha H, Dridi I H (2019). Integrated production, statistical process control, and maintenance policy for unreliable manufacturing systems. International Journal of Production Research, 57(8): 2548–2570

    Google Scholar 

  • Batun S, Maillart L M (2012). Reassessing tradeoffs inherent to simultaneous maintenance and production planning. Production and Operations Management, 21(2): 396–403

    Google Scholar 

  • Berrade M D, Scarf P A, Cavalcante C A (2018). Conditional inspection and maintenance of a system with two interacting components. European Journal of Operational Research, 268(2): 533–544

    MathSciNet  MATH  Google Scholar 

  • Byon E, Ding Y (2010). Season-dependent condition-based maintenance for a wind turbine using a partially observed Markov decision process. IEEE Transactions on Power Systems, 25(4): 1823–1834

    Google Scholar 

  • Chehade A, Bonk S, Liu K (2017). Sensory-based failure threshold estimation for remaining useful life prediction. IEEE Transactions on Reliability, 66(3): 939–949

    Google Scholar 

  • Cheng G Q, Zhou B H, Li L (2018). Integrated production, quality control and condition-based maintenance for imperfect production systems. Reliability Engineering & System Safety, 175: 251–264

    Google Scholar 

  • Cinlar E, Bazant Z P, Osman E M (1977). Stochastic process for extrapolating concrete creep. ACSE Journal of the Engineering Mechanics Division, 103(6): 1069–1088

    Google Scholar 

  • Cipollini F, Oneto L, Coraddu A, Murphy A J, Anguita D (2018). Condition-based maintenance of naval propulsion systems: Data analysis with minimal feedback. Reliability Engineering & System Safety, 177: 12–23

    Google Scholar 

  • de Jonge B (2019). Discretizing continuous-time continuous-state deterioration processes, with an application to condition-based maintenance optimization. Reliability Engineering & System Safety, 188: 1–5

    Google Scholar 

  • de Jonge B, Scarf P A (2020). A review on maintenance optimization. European Journal of Operational Research, 285(3): 805–824

    MathSciNet  MATH  Google Scholar 

  • Do P, Assaf R, Scarf P, Iung B (2019). Modelling and application of condition-based maintenance for a two-component system with stochastic and economic dependencies. Reliability Engineering & System Safety, 182: 86–97

    Google Scholar 

  • Ellingwood B R, Mori Y (1993). Probabilistic methods for condition assessment and life prediction of concrete structure in nuclear power plants. Nuclear Engineering and Design, 142(2–3): 155–166

    Google Scholar 

  • Elwany A H, Gebraeel N Z (2008). Sensor-driven prognostic models for equipment replacement and spare parts inventory. IIE Transactions, 40(7): 629–639

    Google Scholar 

  • Feng Q, Bi X, Zhao X, Chen Y, Sun B (2017). Heuristic hybrid game approach for fleet condition-based maintenance planning. Reliability Engineering & System Safety, 157: 166–176

    Google Scholar 

  • Fitouhi M C, Nourelfath M, Gershwin S B (2017). Performance evaluation of a two-machine line with a finite buffer and condition-based maintenance. Reliability Engineering & System Safety, 166: 61–72

    Google Scholar 

  • Ghamlouch H, Fouladirad M, Grall A (2017). The use of real option in condition-based maintenance scheduling for wind turbines with production and deterioration uncertainties. Reliability Engineering & System Safety, 188: 614–623

    Google Scholar 

  • Gössinger R, Helmke H, Kaluzny M (2017). Condition-based release of maintenance jobs in a decentralised production-maintenance system— An analysis of alternative stochastic approaches. International Journal of Production Economics, 193: 528–537

    Google Scholar 

  • Hanachi H, Mechefske C, Liu J, Banerjee A, Chen Y (2018). Performance-based gas turbine health monitoring, diagnostics, and prognostics: A survey. IEEE Transactions on Reliability, 67(3): 1340–1363

    Google Scholar 

  • Harris F W (1990). How many parts to make at once. Operations Research, 38(6): 947–950

    Google Scholar 

  • He Y, Gu C, Chen Z, Han X (2017). Integrated predictive maintenance strategy for manufacturing systems by combining quality control and mission reliability analysis. International Journal of Production Research, 55(19): 5841–5862

    Google Scholar 

  • Huang Y S, Huang C D, Ho J W (2017). A customized two-dimensional extended warranty with preventive maintenance. European Journal of Operational Research, 257(3): 971–978

    MathSciNet  MATH  Google Scholar 

  • Huynh K T (2020). Modeling past-dependent partial repairs for condition-based maintenance of continuously deteriorating systems. European Journal of Operational Research, 280(1): 152–163

    MathSciNet  MATH  Google Scholar 

  • Huynh K T, Grall A, Bérenguer C (2017). Assessment of diagnostic and prognostic condition indices for efficient and robust maintenance decision-making of systems subject to stress corrosion cracking. Reliability Engineering & System Safety, 159: 237–254

    Google Scholar 

  • Jafari L, Makis V (2015). Joint optimal lot sizing and preventive maintenance policy for a production facility subject to condition monitoring. International Journal of Production Economics, 169: 156–168

    Google Scholar 

  • Jafari L, Makis V (2016). Optimal lot-sizing and maintenance policy for a partially observable production system. Computers & Industrial Engineering, 93: 88–98

    Google Scholar 

  • Jafari L, Makis V (2019). Optimal production and maintenance policy for a partially observable production system with stochastic demand. International Journal of Industrial and Systems Engineering, 13(7): 449–456

    Google Scholar 

  • Jahani S, Kontar R, Zhou S Y, Veeramani D (2020). Remaining useful life prediction based on degradation signals using monotonic B-splines with infinite support. IISE Transactions, 52(5): 537–554

    Google Scholar 

  • Kazaz B, Sloan T W (2008). Production policies under deteriorating process conditions. IIE Transactions, 40(3): 187–205

    Google Scholar 

  • Khatab A, Diallo C, Aghezzaf E H, Venkatadri U (2019). Integrated production quality and condition-based maintenance optimisation for a stochastically deteriorating manufacturing system. International Journal of Production Research, 57(8): 2480–2497

    Google Scholar 

  • Kian R, Bektaç T, Ouelhadj D (2019). Optimal spare parts management for vessel maintenance scheduling. Annals of Operations Research, 272(1–2): 323–353

    MathSciNet  MATH  Google Scholar 

  • Kim H, Kim J T, Heo G (2018). Failure rate updates using condition-based prognostics in probabilistic safety assessments. Reliability Engineering & System Safety, 175: 225–233

    Google Scholar 

  • Kim M, Song C, Liu K (2019). A generic health index approach for multisensor degradation modeling and sensor selection. IEEE Transactions on Automation Science and Engineering, 16(3): 1426–1437

    Google Scholar 

  • Kim M J, Makis V (2013). Joint optimization of sampling and control of partially observable failing systems. Operations Research, 61(3): 777–790

    MathSciNet  MATH  Google Scholar 

  • Kontar R, Zhou S, Sankavaram C, Du X, Zhang Y (2018). Nonparametric-condition-based remaining useful life prediction incorporating external factors. IEEE Transactions on Reliability, 67(1): 41–52

    Google Scholar 

  • Kurt M, Kharoufeh J P (2010). Monotone optimal replacement policies for a Markovian deteriorating system in a controllable environment. Operations Research Letters, 38(4): 273–279

    MathSciNet  MATH  Google Scholar 

  • Lam J Y J, Banjevic D (2015). A myopic policy for optimal inspection scheduling for condition based maintenance. Reliability Engineering & System Safety, 144: 1–11

    Google Scholar 

  • Lee J, Wu F, Zhao W, Ghaffari M, Liao L, Siegel D (2014). Prognostics and health management design for rotary machinery systems—Reviews, methodology and applications. Mechanical Systems and Signal Processing, 42(1–2): 314–334

    Google Scholar 

  • Lee M L T, Whitmore G A (2006). Threshold regression for survival analysis: Modeling event times by a stochastic process reaching a boundary. Statistical Science, 21(4): 501–513

    MathSciNet  MATH  Google Scholar 

  • Levitin G, Xing L, Dai Y (2017). Preventive replacements in real-time standby systems with periodic backups. IEEE Transactions on Reliability, 66(3): 771–782

    Google Scholar 

  • Li R, Ryan J K (2011). A Bayesian inventory model using real-time condition monitoring information. Production and Operations Management, 20(5): 754–771

    Google Scholar 

  • Li Y, Chang Q, Biller S, Xiao G (2014). Event-based modelling of distributed sensor networks in battery manufacturing. International Journal of Production Research, 52(14): 4239–4252

    Google Scholar 

  • Li Y, Tang Q, Chang Q, Brundage M P (2017). An event-based analysis of condition-based maintenance decision-making in multistage production systems. International Journal of Production Research, 55(16): 4753–4764

    Google Scholar 

  • Lin L, Luo B, Zhong S S (2018). Multi-objective decision-making model based on CBM for an aircraft fleet with reliability constraint. International Journal of Production Research, 56(14): 4831–4848

    Google Scholar 

  • Lin X, Basten R J I, Kranenburg A A, van Houtum G J (2017). Condition based spare parts supply. Reliability Engineering & System Safety, 168: 240–248

    Google Scholar 

  • Liu B, Liang Z, Parlikad A K, Xie M, Kuo W (2017a). Condition-based maintenance for systems with aging and cumulative damage based on proportional hazards model. Reliability Engineering & System Safety, 168: 200–209

    Google Scholar 

  • Liu B, Wu S, Xie M, Kuo W (2017b). A condition-based maintenance policy for degrading systems with age- and state-dependent operating cost. European Journal of Operational Research, 263(3): 879–887

    MathSciNet  MATH  Google Scholar 

  • Liu Q M, Dong M, Lv W Y, Ye C M (2019). Manufacturing system maintenance based on dynamic programming model with prognostics information. Journal of Intelligent Manufacturing, 30(3): 1155–1173

    Google Scholar 

  • Liu X, Li J, Al-Khalifa K N, Hamouda A S, Coit D W, Elsayed E A (2013). Condition-based maintenance for continuously monitored degrading systems with multiple failure modes. IIE Transactions, 45(4): 422–435

    Google Scholar 

  • Louit D, Pascual R, Banjevic D, Jardine A K (2011). Condition-based spares ordering for critical components. Mechanical Systems and Signal Processing, 25(5): 1837–1848

    Google Scholar 

  • Ma X Y, Liu B, Yang L, Peng R, Zhang X D (2020). Reliability analysis and condition-based maintenance optimization for a warm standby cooling system. Reliability Engineering & System Safety, 193: 106588

    Google Scholar 

  • Makis V, Jiang X (2003). Optimal replacement under partial observations. Mathematics of Operations Research, 28(2): 382–394

    MathSciNet  MATH  Google Scholar 

  • Olde Keizer M C A, Flapper S D P, Teunter R H (2017a). Condition-based maintenance policies for systems with multiple dependent components: A review. European Journal of Operational Research, 261(2): 405–420

    MathSciNet  MATH  Google Scholar 

  • Olde Keizer M C A, Teunter R H, Veldman J (2017b). Joint condition-based maintenance and inventory optimization for systems with multiple components. European Journal of Operational Research, 257(1): 209–222

    MathSciNet  MATH  Google Scholar 

  • Olde Keizer M C A, Teunter R H, Veldman J, Babai M Z (2018). Condition-based maintenance for systems with economic dependence and load sharing. International Journal of Production Economics, 195: 319–327

    Google Scholar 

  • Peng C Y, Tseng S T (2009). Mis-specification analysis of linear degradation models. IEEE Transactions on Reliability, 58(3): 444–455

    Google Scholar 

  • Peng H, van Houtum G J (2016). Joint optimization of condition-based maintenance and production lot-sizing. European Journal of Operational Research, 253(1): 94–107

    MathSciNet  MATH  Google Scholar 

  • Poppe J, Boute R N, Lambrecht M R (2018). A hybrid condition-based maintenance policy for continuously monitored components with two degradation thresholds. European Journal of Operational Research, 268(2): 515–532

    MathSciNet  MATH  Google Scholar 

  • Shi H, Zeng J (2016). Real-time prediction of remaining useful life and preventive opportunistic maintenance strategy for multi-component systems considering stochastic dependence. Computers & Industrial Engineering, 93(3): 192–204

    Google Scholar 

  • Si X, Li T, Zhang Q, Hu X (2018). An optimal condition-based replacement method for systems with observed degradation signals. IEEE Transactions on Reliability, 67(3): 1281–1293

    Google Scholar 

  • Si X S, Wang W, Hu C H, Zhou D H (2011). Remaining useful life estimation—A review on the statistical data driven approaches. European Journal of Operational Research, 213(1): 1–14

    MathSciNet  Google Scholar 

  • Skordilis E, Moghaddass R (2017). A condition monitoring approach for real-time monitoring of degrading systems using Kalman filter and logistic regression. International Journal of Production Research, 55(19): 5579–5596

    Google Scholar 

  • Sloan T W, Shanthikumar J G (2000). Combined production and maintenance scheduling for a multiple-product, single-machine production system. Production and Operations Management, 9(4): 379–399

    Google Scholar 

  • Song C, Liu K (2018). Statistical degradation modeling and prognostics of multiple sensor signals via data fusion: A composite health index approach. IISE Transactions, 50(10): 853–867

    Google Scholar 

  • Song C, Liu K, Zhang X (2019). A generic framework for multisensor degradation modeling based on supervised classification and failure surface. IISE Transactions, 51(11): 1288–1302

    Google Scholar 

  • Tang S, Guo X, Zhou Z (2014). Mis-specification analysis of linear Wiener process-based degradation models for the remaining useful life estimation. Proceedings of the Institution of Mechanical Engineers, Part O: Journal of Risk and Reliability, 228(5): 478–487

    Google Scholar 

  • Topan E, Tan T, van Houtum G J, Dekker R (2018). Using imperfect advance demand information in lost-sales inventory systems with the option of returning inventory. IISE Transactions, 50(3): 246–264

    Google Scholar 

  • uit het Broek M A J, Teunter R H, de Jonge B, Veldman J, van Foreest N D (2019). Condition-based production planning: Adjusting production rates to balance output and failure risk. Manufacturing & Service Operations Management. In press, doi: https://doi.org/10.1287/msom.2019.0773

  • Verbert K, de Schutter B, Babuška R (2018). A multiple-model reliability prediction approach for condition-based maintenance. IEEE Transactions on Reliability, 67(3): 1364–1376

    Google Scholar 

  • Vogl G W, Weiss B A, Helu M (2016). A review of diagnostic and prognostic capabilities and best practices for manufacturing. Journal of Intelligent Manufacturing, 30(1): 79–95

    Google Scholar 

  • Walter G, Flapper S D (2017). Condition-based maintenance for complex systems based on current component status and Bayesian updating of component reliability. Reliability Engineering & System Safety, 168: 227–239

    Google Scholar 

  • Wan Q, Liu C, Wu Y, Zhou W (2018). A TBE control chart-based maintenance policy for a service facility. Computers & Industrial Engineering, 126: 136–148

    Google Scholar 

  • Wang H K, Huang H Z, Li Y F, Yang Y J (2016). Condition-based maintenance with scheduling threshold and maintenance threshold. IEEE Transactions on Reliability, 65(2): 513–524

    Google Scholar 

  • Wang L, Lu Z Q, Ren Y F (2019). A rolling horizon approach for production planning and condition-based maintenance under uncertain demand. Proceedings of the Institution of Mechanical Engineers, Part O: Journal of Risk and Reliability, 233(6): 1014–1028

    Google Scholar 

  • Wang W (2007). A two-stage prognosis model in condition based maintenance. European Journal of Operational Research, 182(3): 1177–1187

    MATH  Google Scholar 

  • Wang W, Christer A H (2000). Towards a general condition based maintenance model for a stochastic dynamic system. Journal of the Operational Research Society, 51(2): 145–155

    MATH  Google Scholar 

  • Wang X, Xu D (2010). An inverse Gaussian process model for degradation data. Technometrics, 52(2): 188–197

    MathSciNet  Google Scholar 

  • Wei G, Zhao X, He S, He Z (2019). Reliability modeling with condition-based maintenance for binary-state deteriorating systems considering zoned shock effects. Computers & Industrial Engineering, 130: 282–297

    Google Scholar 

  • Wu J, Deng C, Shao X Y, Xie S Q (2009). A reliability assessment method based on support vector machines for CNC equipment. Science in China Series E: Technological Sciences, 52(7): 1849–1857

    MATH  Google Scholar 

  • Wu S (2014). Construction of asymmetric copulas and its application in two-dimensional reliability modelling. European Journal of Operational Research, 238(2): 476–485

    MathSciNet  MATH  Google Scholar 

  • Xu W, Wang W (2013). RUL estimation using an adaptive inverse Gaussian model. Chemical Engineering Transactions, 33: 331–336

    MathSciNet  Google Scholar 

  • Yahyatabar A, Najafi A A (2018). Condition based maintenance policy for series-parallel systems through proportional hazards model: A multi-stage stochastic programming approach. Computers & Industrial Engineering, 126: 30–46

    Google Scholar 

  • Yan T, Lei Y G, Wang B, Han T Y, Si X S, Li N P (2020). Joint maintenance and spare parts inventory optimization for multi-unit systems considering imperfect maintenance actions. Reliability Engineering & System Safety, 202: 106994

    Google Scholar 

  • Ye Z S, Chen N (2014). The inverse Gaussian process as a degradation model. Technometrics, 56(3): 302–311

    MathSciNet  Google Scholar 

  • Ye Z S, Murthy D N P (2016). Warranty menu design for a two-dimensional warranty. Reliability Engineering & System Safety, 155: 21–29

    Google Scholar 

  • Zhang J X, Hu C H, He X, Si X S, Liu Y, Zhou D H (2017). Lifetime prognostics for deteriorating systems with time-varying random jumps. Reliability Engineering & System Safety, 167: 338–350

    Google Scholar 

  • Zhang M, Revie M (2017). Continuous-observation partially observable semi-Markov decision processes for machine maintenance. IEEE Transactions on Reliability, 66(1): 202–218

    Google Scholar 

  • Zhang N, Fouladirad M, Barros A, Zhang J (2020). Condition-based maintenance for a k-out-of-n, deteriorating system under periodic inspection with failure dependence. European Journal of Operational Research, 287(1): 159–167

    MathSciNet  MATH  Google Scholar 

  • Zhang X, Zeng J (2017). Joint optimization of condition-based opportunistic maintenance and spare parts provisioning policy in multiunit systems. European Journal of Operational Research, 262(2): 479–498

    MathSciNet  MATH  Google Scholar 

  • Zhang Z, Si X, Hu C, Lei Y (2018). Degradation data analysis and remaining useful life estimation: A review on Wiener-process-based methods. European Journal of Operational Research, 271(3): 775–796

    MathSciNet  MATH  Google Scholar 

  • Zhao S, Makis V, Chen S, Li Y (2018a). Evaluation of reliability function and mean residual life for degrading systems subject to condition monitoring and random failure. IEEE Transactions on Reliability, 67(1): 13–25

    Google Scholar 

  • Zhao X, He S, He Z, Xie M (2018b). Optimal condition-based maintenance policy with delay for systems subject to competing failures under continuous monitoring. Computers & Industrial Engineering, 124: 535–544

    Google Scholar 

  • Zhou X, Xi L, Lee J (2007). Reliability-centered predictive maintenance scheduling for a continuously monitored system subject to degradation. Reliability Engineering & System Safety, 92(4): 530–534

    Google Scholar 

  • Zhou Z J, Hu C H, Xu D L, Chen M Y, Zhou D H (2010). A model for real-time failure prognosis based on hidden Markov model and belief rule base. European Journal of Operational Research, 207(1): 269–283

    MathSciNet  MATH  Google Scholar 

  • Zhu S, van Jaarsveld W, Dekker R (2020). Spare parts inventory control based on maintenance planning. Reliability Engineering & System Safety, 193: 106600

    Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Wei Jiang.

Additional information

This work is supported by National Natural Science Foundation of China under grants 71531010 and 71831006.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Li, Y., Peng, S., Li, Y. et al. A review of condition-based maintenance: Its prognostic and operational aspects. Front. Eng. Manag. 7, 323–334 (2020). https://doi.org/10.1007/s42524-020-0121-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s42524-020-0121-5

Keywords

Navigation