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

• Published in: Reliability engineering & system safety Vol. 255; p. 110661
• Main Authors: Zhang, Ji, Chen, Xiaohui, An, Youjun, Zhang, Lin, Shi, Haohao, Xu, Weigang
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.03.2025
• Subjects: Analytical solution; Multiple maintenance policies; Preventive maintenance; Product quality; Quality-reliability dependency; Random processing time; Product quality; Multiple maintenance policies; Quality-reliability dependency; Analytical solution; Preventive maintenance; Random processing time
• ISSN: 0951-8320
• DOI: 10.1016/j.ress.2024.110661

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. •Three novel joint optimization policies of preventive maintenance and product quality improvement are proposed.•The coupling relationship between machine reliability and product quality is explored.•Random processing time is incorporated into the joint optimization policies to reduce production interruptions.•Optimization conditions for the proposed three models are discussed mathematically.•The conditions for selecting an appropriate policy under specific production conditions are analytically investigated.