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Reliability evaluation and component importance measure for manufacturing systems based on failure losses

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Abstract

Little work has been done to assess the reliability of a vital system like the manufacturing system. In this article, a novel and effective system reliability evaluation method in terms of failure losses has been proposed for manufacturing systems of job shop type, and then the failure losses based component importance measure (CIM) is used for importance analysis of equipment. The former indicates the present system reliability situation and the latter points the way to reliability improvement efforts. In this scheme, the problem is described and modeled by a dynamic directed network. Consider that the actual processing time of machines is to contribute to failure occurrence, it is used to calculate the failure times and failure losses. The obtained total failure times and failure losses of the system are applied to evaluate its reliability. Techniques to estimate two kinds of failure losses based CIMs are presented. They offer guidelines to realize system reliability growth cost-effectively. A case study of a real job shop is provided as an example to demonstrate the validity of the proposed methods. Comparison to other commonly used methods shows the efficiency of the proposed methods.

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Abbreviations

CIM:

Component importance measure

CNC:

Computer numerical control

DNC:

Distributed numerical control

ERP:

Enterprise resource planning

FT:

Failure times

MES:

Manufacturing execution system

MPT:

Machine processing time

MTBF:

Mean time between failure

MTTF:

Mean time to failure

MTTR:

Mean time to repair

OEE:

Overall equipment effectiveness

RFID:

Radio frequency identification

WDN:

Weighted and directed network

WIP:

Work-in-process

\(t, T\) :

Sequence number of time intervals (number of all intervals is \(T\))

\(i, I_{t}\) :

Sequence number of products items (number of all items is \(I_{t}\))

\(j, J_{t}\) :

Sequence number of processes during \(t\) (\(J_{t}\) is the maximum value)

\(k, K\) :

Sequence number of equipment (number of all equipment is \(K\))

\(G_{t}\) :

WDN during \(t\)

\(M_{k}\) :

Equipment \(k\)

\(r_{k}\) :

Failure rate of \(M_{k}\)

\(FT_{tk}\) :

Failure times of \(M_{k}\) during \(t\)

\(T_{total}\) :

Total time

\(V_{ti}\) :

Volume size of item \(i\) during \(t\)

\(B_{tij}\) :

Processing time of item \(i\) for the \(j\hbox {th}\) process during \(t\)

\(x_{tijk}\) :

Be equal to 1 if \(M_{k}\) is used for machining the \(j\hbox {th}\) process of item \(i\) during \(t\), 0 otherwise

\(MTBF_{k}\) :

MTBF of \(M_{k}\)

\(MTTR_{k}\) :

MTTR of \(M_{k}\)

\(C_{k}\) :

Average maintenance cost for every repair process of \(M_{k}\)

\(PL_{tk}\) :

Production losses for \(M_{k}\) during time period \(t\)

\(C_{k}^{f}\) :

Fixed cost for spare parts or components

\(C_{k}^{v}\) :

Variable cost for labor cost

\(c\) :

Unit labor cost of maintenance crews

\(U_{tijk}\) :

Occupancy rate of \(M_{k}\) processing the \(j\hbox {th}\) process of Item \(i\) during \(t\)

\(s_{i}\) :

Profit for every item \(i\)

\(FT_{total}\) :

Total failure times

\(FL_{total}\) :

Total failure losses

\(\overline{FL}\) :

Average losses of every failure

\(I_{k-MTBF}^{FL}\) :

CIM in terms of \(MTBF_{k}\)

\(I_{k-MTTR}^{FL}\) :

CIM in terms of \(MTTR_{k}\)

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Acknowledgments

The authors are grateful to the Technical Editor and all Reviewers for their valuable and constructive comments. This work was supported by the major national science & technology program (top-grade CNC machine tools and basic manufacturing equipment) under Grant No. 2011ZX04016-101.

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Authors and Affiliations

  1. School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, People’s Republic of China

    Ding Zhang, Yingjie Zhang, Mingrang Yu & Yun Chen

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  1. Ding Zhang
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Correspondence to Ding Zhang.

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Zhang, D., Zhang, Y., Yu, M. et al. Reliability evaluation and component importance measure for manufacturing systems based on failure losses. J Intell Manuf 28, 1859–1869 (2017). https://doi.org/10.1007/s10845-015-1073-1

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