Abstract
As an increasing number of manufacturers are beginning to realize the importance of maintaining throughput, many maintenance models have been developed to enable machines to achieve near-zero downtime. However, previous maintenance models usually ignore machine’s deterioration process. Therefore, this paper develops a novel data-driven machinery prognostic approach for machine performance assessment and prediction. With this prognostic information, a predictive maintenance model is proposed for a repairable deteriorating machine. As machine performance can be assessed, once it reaches the maintenance threshold, a maintenance operation is performed to restore the machine. Moreover, an operational cost is introduced to meet real manufacturing process. In this predictive maintenance model, the optimal maintenance threshold and maintenance cycle number are obtained with the aim to minimize the long-term average cost. Finally, a case study is presented. The computational results show the efficiency of this proposed predictive maintenance model.
Article PDF
Similar content being viewed by others
Explore related subjects
Discover the latest articles, news and stories from top researchers in related subjects.Avoid common mistakes on your manuscript.
References
Tam ASB, Chan WM, Price JWH (2007) Maintenance scheduling to support the operation of manufacturing and production assets. Int J Adv Manuf Technol 34(3–4):399–405
Liao WZ, Pan ES, Xi LF (2009) A condition-based maintenance policy for intelligent monitored system. Int J Comput Appl Technol 35(2–4):104–112
Barlow RE, Hunter LC (1960) Optimum preventive maintenance policies. Oper Res 8(1):90–100
Khandelwal DN, Sharma J, Ray LM (1979) Optimal periodic maintenance of a machine. IEEE Trans Autom Control 24(3):513
Yak YW, Dillon TS, Forward KE (1987) Modelling the effect of transient faults in fault-tolerant computer systems. Comput Syst Sci Eng 2:161–166
Lai MT, Chen YC (2006) Optimal periodic replacement policy for a two-unit system with failure rate interaction. Int J Adv Manuf Technol 29(3–4):367–371
Graves GH, Lee CY (1999) Scheduling maintenance and semiresumable jobs on a single machine. Nav Res Logist 46(7):845–863
. Liao WZ, Pan ES, Xi LF (2007) Dynamic preventive maintenance policy based on health index. The Proceedings of 2007 International Conference on Industrial Engineering and Engineering Management 1–4, pp 930–934
Liao WZ, Pan ES, Xi LF (2010) Preventive maintenance scheduling for repairable system with deterioration. J Intell Manuf 21(6):875–884
Badia FG, Berrade MD, Campos CA (2002) Optimal inspection and preventive maintenance of units with revealed and unrevealed failures. Reliab Eng Syst Saf 78(2):157–163
El-Ferik S, Ben-Daya M (2006) Age-based hybrid model for imperfect preventive maintenance. IIE Trans 38(4):365–375
Pan ES, Liao WZ, Zhuo ML (2010) Periodic preventive maintenance policy with infinite time and limit of reliability based on health index. J Shanghai Jiaotong Univ (Science) 15(2):231–235
Zhou XJ, Xi LF, Lee J (2007) Reliability-centered predictive maintenance scheduling for a continuously monitored system subject to degradation. Reliab Eng Syst Saf 92(4):530–534
Tian ZG, Liao HT (2011) Condition based maintenance optimization for multi-component systems using proportional hazards model. Reliab Eng Syst Saf 96(5):581–589
Greenough MR, Grubic T (2011) Modelling condition-based maintenance to deliver a service to machine tool users. Int J Adv Manuf Technol 52(9–12):1117–1132
Lee J, Ni J, Djurdjanovic D, Qiu H, Liao HT (2006) Intelligent prognostic tools and e-maintenance. Comput Ind 57(6):476–489
Fan HD, Hu CH, Chen MY et al (2011) Cooperation predictive maintenance of repairable systems with dependent failure modes and resource constraint. IEEE Trans Reliab 60(1):144–157
Hashemian HM (2011) State-of-the-art predictive maintenance techniques. IEEE Trans Instrum Meas 60(1):226–236
Pan ES, Liao WZ, Xi LF (2010) Single-machine-based production scheduling model integrated preventive maintenance planning. Int J Adv Manuf Technol 50(1–4):365–375
You MY, Li L, Meng G, Ni J (2010) Cost-effective updated sequential predictive maintenance policy for continuously monitored degrading systems. IEEE Trans Autom Sci Eng 7(2):257–265
Ruel M (2005) Performance monitoring and supervision: an economic point of view. Tech Pap ISA 459:139–151
Svensson B (2006) Power plant efficiency information key to operational cost savings. Diesel Gas Turbine Worldw 38(1):50–51
Heidergott B, Farenhorst-Yuan T (2010) Gradient estimation for multicomponent maintenance systems with age-replacement policy. Oper Res 58(3):706–718
Golmakani H, Fattahipour F (2010) Optimal replacement policy with age-based inspection scheme for condition-based maintenance. IEEE International Conference on Information Reuse and Integration, pp 253–257
Ross S (1970) Applied probability models with optimization application. Holden-Day, San Diego
Lee CY (1996) Machine scheduling with an availability constraint. J Glob Optim 9(3–4):395–416
Jardine KSA, Lin D, Banjevic D (2005) A review on machinery diagnostics and prognostics implementing condition-based maintenance. Mech Syst Signal Process 20(7):1483–1510
Kothamasu R, Huang S, VerDuin HW (2006) System health monitoring and prognostics-a review of current paradigms and practices. Int J Adv Manuf Technol 28(9–10):1012–1024
Heng A, Zhang S, Tan A, Mathew J (2009) Rotating machinery prognostic: state of the art, challenges and opportunities. Mech Syst Signal Process 23(3):724–739
Ao Y, Qiao G (2010) Prognostics for drilling process with wavelet packet decomposition. Int J Adv Manuf Technol 50(1–4):47–52
Pipe K (2008) Practical prognostics for condition based maintenance. Int Conf Prog Health Manag, PHM 2008:1–10
Kaiser KA, Gebraeel NZ (2009) Predictive maintenance management using sensor-based degradation models. IEEE Trans Syst Man Cybern A: Syst Hum 39(4):840–849
Lu B, Durocher DB, Stemper P (2009) Predictive maintenance techniques. IEEE Ind Appl Mag 15(6):52–60
Schwarz G (1978) Estimating the dimension of a model. Ann Stat 6(2):461–464
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Liao, W., Wang, Y. & Pan, E. Single-machine-based predictive maintenance model considering intelligent machinery prognostics. Int J Adv Manuf Technol 63, 51–63 (2012). https://doi.org/10.1007/s00170-011-3884-3
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-011-3884-3