A hybrid deep learning approach to integrate predictive maintenance and production planning for multi-state systems

Abstract

This paper develops a data-driven approach to dynamically integrate tactical production and predictive maintenance planning for a multi-state system composed of several series-parallel machines. The objective is to determine an integrated lot-sizing and preventive maintenance strategy that will minimize the sum of maintenance and production costs, while satisfying the demand for all products over the entire horizon. A rolling horizon planning strategy is adopted to continuously update the production and maintenance plans based on new data obtained through sensors. Unlike the existing integrated models, we develop a hybrid deep learning (DL) approach to coordinate maintenance and production decisions for a multi-state system composed of multiple machines. To accurately predict the health condition of each machine, the developed hybrid DL method combines the powers of convolutional neural network (CNN), long-short-term memory (LSTM), and attention technique. We use multi-state reliability theory to estimate the production capacity. Furthermore, a genetic algorithm is developed to solve large-scale problems. Benchmarking data are used to compare the results of our data-driven approach with a model-based approach, a pure LSTM, and a CNN-LSTM approach. This comparison is based on prediction accuracy, solution quality, and computational time. The obtained results show the superiority of the suggested CNN-LSTM-attention data-driven framework integrating maintenance and production.