Joint optimization of preventive maintenance and product quality improvement policies for deteriorating manufacturing systems with quality-reliability dependency

IF 9.4 1区工程技术 Q1 ENGINEERING, INDUSTRIAL Reliability Engineering & System Safety Pub Date : 2024-11-23 DOI:10.1016/j.ress.2024.110661

Ji Zhang , Xiaohui Chen , Youjun An , Lin Zhang , Haohao Shi , Weigang Xu

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Abstract

Machine reliability and product quality are usually investigated independently in most traditional models. However, in the actual manufacturing process, machine reliability and product quality are commonly interdependent due to strong coupling between the machine and the product. In this paper, three joint optimization models for preventive maintenance (PM) and product quality improvement are developed for deteriorating manufacturing systems considering quality-reliability dependency. First, the degradation process of quality-related components (QRCs) is depicted by Gamma process, and product quality deviation is obtained by considering the quantitative relationship between the degradation of QRCs and product quality. Second, joint optimization policy of age-based maintenance and product quality improvement is proposed for deteriorating manufacturing systems with quality-reliability dependency. Third, above maintenance policy is extended to manufacturing systems processing jobs with random processing time, and then maintenance first (MF) and maintenance last (ML) policies are developed, respectively. Furthermore, we compare all of the maintenance models to determine which policy should be selected for manufacturing systems under specific conditions, and all theoretical discussions in this paper are analytically made. Finally, the effectiveness of the proposed joint policies is verified by a case study on a cylindrical gear housing machining process.

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具有质量可靠性依赖的恶化制造系统的预防性维护和产品质量改进政策的联合优化

在大多数传统模型中，机器可靠性和产品质量通常是独立研究的。然而，在实际制造过程中，由于机器和产品之间的强耦合，机器可靠性和产品质量通常是相互依赖的。针对退化制造系统，考虑质量-可靠性依赖关系，建立了预防性维修与产品质量改进联合优化模型。首先，采用Gamma过程描述质量相关部件的降解过程，考虑质量相关部件降解与产品质量的定量关系，得到产品质量偏差；其次，针对质量可靠性依赖的恶化制造系统，提出了基于年龄的维修与产品质量改进的联合优化策略。第三，将上述维修策略推广到加工时间随机的制造系统加工作业中，分别制定了先维修（MF）和后维修（ML）策略。此外，我们比较了所有的维护模型，以确定制造系统在特定条件下应该选择哪种策略，并对本文的所有理论讨论进行了分析。最后，以圆柱齿轮壳加工为例，验证了所提联合策略的有效性。

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来源期刊

Reliability Engineering & System Safety 管理科学-工程：工业

CiteScore

15.20

自引率

39.50%

发文量

621

审稿时长

67 days

期刊介绍： Elsevier publishes Reliability Engineering & System Safety in association with the European Safety and Reliability Association and the Safety Engineering and Risk Analysis Division. The international journal is devoted to developing and applying methods to enhance the safety and reliability of complex technological systems, like nuclear power plants, chemical plants, hazardous waste facilities, space systems, offshore and maritime systems, transportation systems, constructed infrastructure, and manufacturing plants. The journal normally publishes only articles that involve the analysis of substantive problems related to the reliability of complex systems or present techniques and/or theoretical results that have a discernable relationship to the solution of such problems. An important aim is to balance academic material and practical applications.