Integrated condition-based maintenance and quality improvement model for deteriorating single-machine manufacturing systems considering condition indicator

Abstract

Condition-based maintenance (CBM) can effectively ameliorate the manufacturing system reliability and the quality of product. Condition indicator (CI) is a comprehensive way to reflect the manufacturing system condition by collected sensor data. However, quality improvement combined with CI has been seldom considered in the most existing CBM models, which leads to economic loss. In this paper, an integrated CBM model is proposed. First, the manufacturing system degradation variables that lead to product quality deterioration are identified and a system failure rate model is established. Second, the CI is used to reflect the condition of the manufacturing system and is further compared with the CBM threshold to decide whether to implement maintenance activity. Third, a process model is employed to quantitatively analysis the relationship between degradation variables and product quality and calculate the quality loss cost. The optimal CBM policy is obtained by minimizing the total cost per unit operating time. Finally, a case study is performed to verify the effectiveness of the integrated CBM model.