Integrated Optimization Model for Maintenance Policies and Quality Control Parameters for Multi-Component System

Abstract

The practical applications of integrated maintenance policies and quality for a multi-component system are more complicated, still rare, and incomplete to meet the requirements of Industry 4.0. Therefore, this work aims to extend the integration economic model for optimizing maintenance policies and quality control parameters by incorporating the Taguchi loss function for a multi-component system. An optimization model is developed based on preventive maintenance, corrective maintenance policies, and quality control parameters with the CUSUM (Cumulative Sum) chart, which is widely used for detecting small shifts in the process mean. The model was developed to minimize the expected total cost per unit of time and to obtain the optimal values of decision variables: the size of samples, sample frequency, decision interval, coefficient of the CUSUM chart, and preventive and corrective maintenance intervals. The solution steps were employed by selecting a case study in the Alahlia Mineral Water Company (AMWC). Then, the design of experiments based on one-factor-at-a-time was used to evaluate the effect of selected decision variables on the expected total cost. Finally, sensitivity analysis was performed on the selected decision variables to demonstrate the robustness of the developed model. A predictive maintenance plan was developed based on the optimal value of preventive maintenance interval, and the results showed that the performance of the maintenance plan realizes the full potential of the integrated model. In addition, the case study results indicate that the extended integrated model for multicomponent is the new standard for the quality production of multi-component systems in future works.