Reliability analysis of standby provision multi‐unit machining systems with varied failures, degradations, imperfections, and delays

Abstract

This prospective study focuses on analyzing the reliability characteristics of multi‐unit systems with standby provisioning, accounting for failures, degradation, random delays, and probabilistic imperfections. The investigation sheds light on how these unreliable attributes hinder the performance and availability of machining systems. Given the frequent occurrence of these negative attributes within machining systems, their impact on production flow, performance, and resource utilization is significant. Moreover, these unfavorable attributes hinder the adoption of advanced technologies that rely on the continuous availability of machining systems. Thorough research on operational traits serves as a foundation for developing solutions to enhance machining system efficiency and elucidates the underlying causes of machining system failures throughout their performance lifecycle. The reliability analysis employs a state‐of‐the‐art queue‐theoretic approach. In order to model the stochastic behavior of the investigated machine repair problem in a systematic manner, we consider various statistically independent failure modes, including active/standby unit failure, degraded failure, switching failure, and common‐cause failure. The unreliable characteristics of machining systems are further compounded by factors such as imperfect fault coverage, reboot delay, and imperfect repair, necessitating a comprehensive examination to strategically implement preventive, corrective, and predictive measures. The seamless operation of multi‐unit machining systems is essential for the successful integration of advanced technologies such as cloud computing, industry 4.0, and IoT. Failures, delays, degradation, and imperfections within machining systems have detrimental effects on their efficiency and availability, demanding in‐depth investigation. To facilitate numerical experimentation and sensitivity analysis of the reliability aspects of the proposed machining system, we develop performance indices such as system reliability, mean‐time‐to‐failure, and failure frequency. These metrics provide valuable insights for decision‐makers seeking to implement measures that ensure uninterrupted availability of the machining system.