Cost-oriented predictive maintenance based on mission reliability state for cyber manufacturing systems

Abstract

With the advent of Industry 4.0, maintenance strategy faces new demands to avoid the hysteresis of the conventional passive maintenance mode and the non-feasibility of the periodic preventive maintenance model. In view of the inherent polymorphism of manufacturing systems and with the objective of maximizing benefits, a novel cost-oriented predictive maintenance based on mission reliability state for manufacturing systems is proposed. First, the cyber-physical system is adopted to organize and analyze big data in the operational process of manufacturing systems in terms of predictive analytics in cyber manufacturing environment. Second, a new connotation of mission reliability is defined based on the big operational data to comprehensively characterize the dynamic state of the equipment health states and the qualified degree of the production task. Third, the predictive maintenance mode based on mission reliability state is quantified by the comprehensive cost, and the relationship between mission reliability and cost is established. Thereafter, costoriented dynamic predictive maintenance strategy is proposed. Finally, a case study on the maintenance decision-making problem of a cylinder head manufacturing system is presented. The final result shows that the comprehensive cost can be further reduced by the proposed method relative to the traditional periodic preventive maintenance strategy.

A manutenção de ativos no contexto da Indústria 4.0: uma análise bibliométrica e sistemática

“…A adesão às tecnologias da Indústria 4.0 propicia um avanço na manutenção preditiva, ou seja, faculta monitorar os equipamentos de forma constante de modo a prever falhas de maneira prematura (He et al, 2018;Guizzi et al, 2019;Bengtsson & Lundström, 2018;Romero-Torres et al, 2017;Tedeschi et al, 2018;Adu-Amankwa et al, 2019).…”

“…Este tema foi estabelecido pois uma estratégia de manutenção de ativos adequada e otimizada é necessária para manter ou restaurar o sistema em um estado em que o equipamento pode completar as tarefas de produção necessárias com custos mínimos. (Changyou, Haiyang, Song, Yimin, & Zhenyuan, 2014;He, Han, Gu, & Chen, 2018;Xia, Xi, Lee, & Zhou, 2011).…”

“…De modo a maximizar os benefícios, He et al (2018) propuseram um novo modelo de manutenção preditiva orientada a custos, baseada no estado de confiabilidade dos sistemas de manufatura. Utilizou-se um sistema ciber-físico para organizar e analisar o Big Data no processo operacional dos sistemas de manufatura em termos de análise preditiva.…”

Mission Reliability-Oriented Selective Maintenance Optimization for Intelligent Multistate Manufacturing Systems With Uncertain Maintenance Quality

“…Multistate manufacturing systems differ from general multistate systems. The reliability modeling of multistate manufacturing systems should comprehensively analyze machines, raw materials, and production tasks [24], [25]. Evidently, a multistate manufacturing system should be modeled with the complete understanding of its operating mechanism.…”

Product infant failure risk modeling based on quality variation propagation and functional failure dependency

“…For example, if a proactive infant failure risk analysis for Samsung Galaxy Note 7 exists, 4 then the painful damage due to battery explosion may be remarkably reduced or avoided. Specifically, infant failures are concentrated embodiments of accumulation of product manufacturing quality variation, 5 and these failures are the important sources of product quality risk. 6 Regarding the quality variation propagation and its influence on infant failure, Huang and Shi 7 proposed the stream of variation (SoV) method to analyze the transmission, connection, and accumulation of quality variations in multistage manufacturing process.…”