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Inspection interval optimization for complex equipment in automotive manufacturing under dependent failures

Optimierung der Inspektionsintervalle für komplexe Geräte in der Automobilherstellung bei abhängigen Ausfällen

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Abstract

Inspection activities in automotive manufacturing play a crucial role in diagnosing and preventing unexpected failures by adopting the well-planned intervals. However, finding the optimal inspection intervals has been a major concern within manufacturing systems due to the failure dependency issue caused by the design complexity and integrated operations. Hence, this paper proposes a new framework for inspection interval optimization under failure dependency in three steps; firstly identifying all failure modes and potential dependent failures through Failure Mode and Effect Analysis (FMEA) method, secondly, adapting the statistical based approach for reliability and availability evaluation, as well as using the Bayesian theory for availability and total expected cost based inspection modeling under failure dependency and finally, performing some well-known Multi-Criteria Decision-Making (MCDM) techniques for finding the optimal trade-off between main criteria e.g. total expected cost and reliability indices. The results of the proposed framework revealed that the failure dependency has a meaningful impact on inspection intervals. Besides, the cost-based model suggests shorter inspection intervals with that of the availability-based model in all dependent failure cases. As a consequence, the results could be useful for implementing the reliable maintenance programs to improve the operational performance of complex equipment in automotive manufacturing.

Zusammenfassung

Inspektionstätigkeiten in der Automobilherstellung spielen eine entscheidende Rolle bei der Diagnose und Vermeidung unvorhergesehener Ausfälle durch die Anwendung gut geplanter Intervalle. Allerdings ist die Bestimmung der optimalen Inspektionsintervalle in Produktionssystemen aufgrund der Fehlerabhängigkeit ein wesentliches Thema, das durch die Komplexität der Konstruktion und die integrierten Prozesse verursacht wird. Deshalb bietet diese Veröffentlichung einen neuen Mechanismus zur Optimierung von Inspektionsintervallen unter Berücksichtigung der Fehlerabhängigkeit in drei Schritten: zunächst Identifikation aller Fehlerarten und möglichen abhängigen Fehler durch die Methode FMEA (Failure Mode and Effect Analysis), zweitens die Anpassung des statistischen Ansatzes für die Zuverlässigkeits- und Verfügbarkeitsanalyse sowie die Verwendung der Bayes’schen Theorie für die Modellierung der Verfügbarkeit und der erwarteten Gesamtkosten bei der Inspektion unter Beachtung der Fehlerabhängigkeit und zum Schluss die Umsetzung verschiedener bekannter MCDM-Techniken (Multi-Criteria Decision-Making) zur Erkennung des optimalen Kompromisses zwischen den Hauptkriterien, z. B. den erwarteten Gesamtkosten und den Zuverlässigkeitsindizes. Die Ergebnisse des vorgestellten Konzepts zeigten, dass die Fehlerabhängigkeit einen deutlichen Einfluss auf die Inspektionsintervalle aufweist. Daneben empfiehlt das kostenorientierte Modell kürzere Inspektionsintervalle im Vergleich zu dem verfügbarkeitsorientierten Modell in allen abhängigen Fehlerfällen. Aus diesem Grunde liefern die Ergebnisse wichtige Hinweise zur Umsetzung von zuverlässigen Wartungsprogrammen, um die Betriebsleistung komplexer Geräte in der Automobilproduktion zu verbessern.

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Funding

The authors gratefully acknowledge the financial support from the Ferdowsi University of Mashhad, Iran (No. FUM-52316), which has been research project.

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Authors and Affiliations

  1. Department of Biosystems Engineering, Ferdowsi University of Mashhad, Mashhad, Iran

    Hamzeh Soltanali, Mehdi Khojastehpour, Esmaeil Rezaei & Abbas Rohani

  2. Department of Industrial Engineering, Mazandaran University of Science and Technology, Mazandaran, Iran

    Esmaeil Rezaei

Authors
  1. Hamzeh Soltanali
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  2. Mehdi Khojastehpour
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  3. Esmaeil Rezaei
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  4. Abbas Rohani
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Correspondence to Mehdi Khojastehpour.

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Conflict of interest

H. Soltanali, M. Khojastehpour, E. Rezaei and A. Rohani declare that they have no competing interests.

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Soltanali, H., Khojastehpour, M., Rezaei, E. et al. Inspection interval optimization for complex equipment in automotive manufacturing under dependent failures. Forsch Ingenieurwes 86, 105–122 (2022). https://doi.org/10.1007/s10010-021-00568-6

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