Maintenance Of Manufacturing Systems Research Articles

A Review on Reliability Modeling of Manufacturing Systems Considering the Production Quality and Equipment Reliability

Background: Nowadays, the manufacturing industry is much more fiercely competitive and global than ever before. For sustainable increases in market share and profitability, manufacturers are aiming to improve the quality of products and maintain the reliability of manufacturing systems. Objective: Therefore, to simultaneously optimize the quality and reliability for manufacturing systems has become an important research topic in recent years. Methods: This study presents an overview of the methods for modeling manufacturing systems, especially considering the system reliability and the product quality. And then, we review the optimization methods for manufacturing system maintenance and production strategy. Conclusion: Finally, optimization methods and some challenges are summarized for future studies.

Semi-Double-loop machine learning based CPS approach for predictive maintenance in manufacturing system based on machine status indications

The paper presents two original and innovative contributions: 1) the model of machine learning (ML) based approach for predictive maintenance in manufacturing system based on machine status indications only, and 2) semi-Double-loop machine learning based intelligent Cyber-Physical System (I-CPS) architecture as a higher-level environment for ML based predictive maintenance execution. Considering only the machine status information provides rapid and very low investment-based implementation of an advanced predictive maintenance paradigm, especially important for SMEs. The model is validated in real-life situations, exploring different learning algorithms and strategies for learning maintenance predictive models. The findings show very high level of prediction accuracy.

An integrated model based on statistical process control and maintenance for two-stage dependent processes

ABSTRACTThe close relationship between quality and maintenance of manufacturing systems has contributed to the development of integrated models which use the concept of statistical process control (SPC) and maintenance. This article demonstrates the integration of the Shewhart individual-residual (ZX − Ze) joint control chart and maintenance for two-stage dependent processes by jointly optimizing their policies to minimize the expected total costs associated with quality, maintenance and inspection. To evaluate the effectiveness of the proposed model, two stand-alone models—a maintenance model and an SPC model—are proposed. Then a numerical example is given to illustrate the application of the proposed integrated model. The results show that the integrated model outperforms the two stand-alone models with regard to the expected cost per unit time. Finally, a sensitivity analysis is conducted to develop insights into time parameters and cost parameters that influence the integration efforts.

MAINTENANCE PERFORMANCE METRICS FOR MANUFACTURING INDUSTRY

The purpose of this paper is to demonstrate various maintenance performance indicators (MPIs) within the perspective of maintenance metrics conducted by the managerial personnel for achieving the specified production target. In this paper, a conceptual framework has been developed, that provides guideline for choosing maintenance performance metrics for a typical manufacturing industry. It seeks to align maintenance objective with the performance indicators and provides a link between the two. Operations and maintenance of manufacturing system are of great economic importance. The review of literature on maintenance performance indicators and their measurement has been summarized under the five categories of metrics; functional metrics, equipment performance metrics, maintenance process metrics, periodicity metrics and OEE metrics. The review indicates that quantitative metrics for measuring maintenance performance are lacking. To address this gap, maintenance performance metrics has been proposed.

A genetic algorithm approach for production scheduling with mould maintenance consideration

The traditional approach for maintenance scheduling concerns single-resource (machine) maintenance during production which may not be sufficient to improve production system reliability as a whole. Besides, in the literature many researchers schedule maintenance activities periodically with fixed maintenance duration. However, in a real manufacturing system maintenance activities can be executed earlier and the maintenance duration will become shorter since less time and effort are required. A practical example is that in a plastic production system, the proportion of machine-related downtime is even lower than mould-related downtime. The planned production operations are usually interrupted seriously because of the mismatch among the maintenance periods between injection machine and mould. In this connection, this paper proposes to jointly schedule production and maintenance tasks of multi-resources in order to improve production system reliability by reducing the mismatch among various processes. To integrate machine and mould maintenance tasks in production, this paper attempts to model the production scheduling with mould scheduling (PS-MS) problem with time-dependent deteriorating maintenance schemes. The objective of this paper is to propose a genetic algorithm approach to schedule maintenance tasks jointly with production jobs for the PS-MS problem, so as to minimise the makespan of production jobs.

An integrated model based on statistical process control and maintenance

The close relationship between quality and maintenance of manufacturing systems has contributed to the development of integrated models, which use the concept of statistical process control (SPC) and maintenance. Such models not only help to improve quality of products but also lead to lower maintenance cost. In this paper, an integrated model is presented which considers complete failure and planned maintenance simultaneously. This model leads to six different scenarios. A new procedure for calculating average cost per time unit is also presented. Finally, a numerical example is used to evaluate sensitivity of the model parameters and compare performance of the developed model to a planned maintenance model. Results indicate satisfactory performance for the developed model.

3212 製造ラインにおけるレーザ溶接システムのメンテナンスの省力化に関する取り組み(OS5-2 効率化,環境負荷低減の技術,OS5 安全・安心・防災・環境負荷低減,オーガナイズド・セッション)

Recently, laser welding technologies have been applied as one of the technologies to manufacture railway vehicles. Maintenance of manufacturing system is an important factor in quality control and the same is true of maintenance of laser welding system. Therefore, in order to realize effective maintenance to prevent quality loss in laser welding, laser welding processes are divided into three processes (pre-process, in-process and post-process) and condition monitoring technologies by waveform analysis obtained from measurement of condition of each process have been developed. This report describes the cases where laser welding monitoring system which intensively utilizes these technologies has been constructed and applied to welding of stainless steel.

Preventive maintenance of manufacturing systems under environmental constraints

The paper describes a new preventive maintenance approach for manufacturing systems under environment constraints. The manufacturing system under consideration consists of a machine M1 that produces a single product in a Just-in-Time context. To satisfy a constant demand d, the system called upon another machine M2 (the subcontractor), comprising the so-called environment, which produces at a certain rate the same type of product as M1. Both machines are subjected to random failures. Whereas machine M2 is uncontrollable from the maintenance point of view, an age-limit policy is used for preventive maintenance of machine M1. It is proved that the best age to perform preventive maintenance depends on the history of machine M1 and the state of M2. A numerical example is used to illustrate the proposed approach.

Enactment of IDEF0 models

This paper presents an integrated approach to the enactment of IDEF0 models to facilitate the development and maintenance of responsive and coherent manufacturing systems. The approach basically involves the enhancement of an IDEF0 model to include additional information about system behaviour and IT infrastructural aspects; and the use of a computer simulator to read and interpret the enhanced IDEF0 model, simulate the model, and control the actual activities. The approach allows a seamless transition from system modelling, through simulation, to maintenance. It is expected that such an approach will greatly expedite the development and maintenance of manufacturing systems. A prototype software tool has been developed at the Gintic Institute of Manufacturing Technology to support the integrated approach.

Empirical study of attitudes to teamworking in manufacturing system maintenance

This paper describes a study of attitudes to team working in an engine plant of a major UK motor manufacturer. The aim of the study was to identify causes of resistance to teamworking and suggest possible solutions. A survey was designed to obtain input from the workers and, in addition, workers were interviewed. The results indicated that workers valued the chance to interact more and get to know each other better. However, they felt strongly that there was not enough communication between the company management and the teams.