scholarly journals A Research on the Combined Maintenance Strategy for Production Line Equipment Based on Mixed Failure Rate

2021 ◽  
Vol 2021 ◽  
pp. 1-15
Author(s):  
Binbin Xu ◽  
Ziyue Wang ◽  
Wei Luo ◽  
Tianqi Ma ◽  
Hao Huang
Keyword(s):  
Failure Rate ◽  
Production Line ◽  
Optimal Number ◽  
Entropy Method ◽  
Maintenance Cost ◽  
Analytic Hierarchy ◽  
Maintenance Costs ◽  
Cost Rate ◽  
Age Regression ◽  
Optimal Maintenance

In order to improve the reliability of the production line and reduce its maintenance costs, this paper establishes preventive maintenance (PM) models of the equipment, which are classified into different levels based on mixed failure rate. The differential and targeted maintaining strategies are formulated as well. First, a method for dividing important equipment and secondary equipment of a production line based on grey interval Analytic Hierarchy Process- (AHP-) Entropy method is proposed. Next, the dynamic service age regression factor and the dynamic failure rate increasing factor are combined to establish a mixed failure rate model. Finally, for the important equipment and secondary equipment, two PM models are established with the constraint of reliability, the objective of maximum availability, and minimum maintenance cost rate to determine the optimal number of PM and cycles. Combined with an example of production line equipment, the optimal maintenance strategies for important equipment and secondary equipment are obtained. The result verified the feasibility of the model, which effectively improved the reliability of the production line equipment and reduced maintenance costs.

Maintenance optimization for marine mechanical systems

2019 ◽  
Vol 234 (2) ◽  
pp. 446-462
Author(s):  
David Kimera ◽  
Fillemon Nduvu Nangolo
Keyword(s):  
Mechanical System ◽  
Expert Knowledge ◽  
Mechanical Systems ◽  
Maintenance Cost ◽  
Maintenance Policy ◽  
Maintenance Costs ◽  
Cost Rate ◽  
Optimal Maintenance ◽  
Optimal Maintenance Policy ◽  
Marine Vehicle

This article proposes a stochastic technique for determining the optimal maintenance policy for marine mechanical systems. The optimal maintenance policy output includes the average maintenance cost rate, maintenance interval and the performance thresholds for the three marine mechanical system classifications. The purpose of this study is to optimize maintenance, maintenance interval and performance thresholds based on maintenance and reliability data of the marine mechanical systems. Performance threshold and maintenance interval are used as the decision variables to determine the optimal maintenance policy. A stochastic model based on probability analysis is developed to trigger the maintenance action for mechanical systems. The model is later coded in MATLAB. Maintenance and failure data for a marine vehicle were statistically fitted using ReliaSoft, from which a three-parameter Weibull distribution best fitted all the mechanical system classifications. Model inputs were based on both the maintenance data and expert knowledge of the maintenance crew. Based on a 20-year marine vehicle life span, the optimal maintenance costs for plant and machinery are relatively the same. The model predicted annual total maintenance cost of US$183,029.24 is 11.11% more than the maintenance cost derived from experts’ threshold of US$164,726. Marine vehicle machinery presents a higher maintenance interval of 3.23 years compared to 2.92 years for marine vehicle plants. It was observed that for the performance thresholds greater than 84.54%, there is an insignificant difference between the plant and machinery maintenance costs. Sensitivity analysis results suggest there is little justification that changing maintenance costs will have an impact on the performance threshold [Formula: see text] and maintenance interval [Formula: see text]. A maintenance interval of 3 years results in a lower total annual maintenance cost deviation of 2.66% from the optimal total annual maintenance cost.

Analysis of Disassembled Module with Damage Model for Recycling

2006 ◽  
Vol 532-533 ◽  
pp. 177-180
Author(s):  
Yong Ji ◽  
Hirohisa Narita ◽  
Lian Yi Chen ◽  
Hideo Fujimoto
Keyword(s):  
Damage Model ◽  
Life Time ◽  
Optimal Number ◽  
Cumulative Damage ◽  
Maintenance Cost ◽  
Damage Level ◽  
Cost Rate ◽  
Optimal Maintenance ◽  
Cumulative Damage Model ◽  
Prime Problem

As environmental problems have become more serious, a sustainable society is necessary. To realize the inverse manufacturing system the prime problem is how to improve the rate of reusing the product modules. Therefore analyzing the life-time of the disassembled modules is very important before reassembling process. In this paper, a cumulative damage model is proposed to discuss the quality of the product that is assembled by reuse modules. It is supposed that modules suffer damages due to shocks and fails when the cumulative damage level exceeds the failure level. Then maintenance cost will be analyzed in order to minimize the expected maintenance cost-rate by optimal maintenance time T and optimal number of damages N in this cumulative damage model. The probable safe life-time of module reuse will be explored. Finally numerical examples are given to confirm the validity of the proposed model.

Availability analysis and maintenance optimization for multiple failure mode systems considering imperfect repair

2021 ◽  
pp. 1748006X2110127
Author(s):  
Qingan Qiu ◽  
Baoliang Liu ◽  
Cong Lin ◽  
Jingjing Wang
Keyword(s):  
Failure Modes ◽  
Maintenance Cost ◽  
Imperfect Maintenance ◽  
Maintenance Policy ◽  
Cost Rate ◽  
Availability Analysis ◽  
Long Run ◽  
Optimal Maintenance ◽  
Maintenance Policies ◽  
Periodic Inspections

This paper studies the availability and optimal maintenance policies for systems subject to competing failure modes under continuous and periodic inspections. The repair time distribution and maintenance cost are both dependent on the failure modes. We investigate the instantaneous availability and the steady state availability of the system maintained through several imperfect repairs before a replacement is allowed. Analytical expressions for system availability under continuous and periodic inspections are derived respectively. The availability models are then utilized to obtain the optimal inspection and imperfect maintenance policy that minimizes the average long-run cost rate. A numerical example for Remote Power Feeding System is presented to demonstrate the application of the developed approach.

The Evaluating and Quantizing of Human Factors at Workplace

2011 ◽  
Vol 328-330 ◽  
pp. 1045-1048 ◽  
Author(s):  
Pu Hong Li ◽  
Jun Zhou ◽  
Jian Xin Deng ◽  
Zhi Jun Fan
Keyword(s):  
Human Factors ◽  
Analytic Hierarchy Process ◽  
Production Line ◽  
Scientific Evidence ◽  
Entropy Method ◽  
Assessment Methods ◽  
Operating Efficiency ◽  
Analytic Hierarchy ◽  
Working Posture ◽  
Hierarchy Process

This paper is focused on the human factors and assessment methods at workplace firstly. Then the human factors are analysed and evaluated to quantized by Analytic Hierarchy Process and Entropy method. On that basis, the multicriteria quantizing model is build, at last the human factors at piston production line as an example is given. According to the result of model, it provides a scientific evidence to make the human factors in difference processes perfect: improving operating efficiency, optimizing working posture.

Optimization of equal-cycle maintenance strategy considering imperfect preventive maintenance

2021 ◽  
pp. 095440892110638
Author(s):  
Xinlong Li ◽  
Yan Ran ◽  
Genbao Zhang
Keyword(s):  
Decision Making ◽  
Preventive Maintenance ◽  
Maintenance Cost ◽  
Maintenance Strategy ◽  
Action Unit ◽  
Cost Rate ◽  
Equipment Reliability ◽  
Optimal Maintenance ◽  
Important Means ◽  
Maintenance Decision

Preventive maintenance is an important means to extend equipment life and improve equipment reliability. Traditional preventive maintenance decision-making is often based on components or the entire system, the granularity is too large and the decision-making is not accurate enough. The meta-action unit is more refined than the component or system, so the maintenance decision-making based on the meta-action unit is more accurate. Therefore, this paper takes the meta-action unit as the research carrier, considers the imperfect preventive maintenance, based on the hybrid hazard rate model, established the imperfect preventive maintenance optimization model of the meta-action unit, and the optimization solution algorithm was given for the maintenance strategy. Finally, through numerical analysis, the validity of the model is verified, and the influence of different maintenance costs on the optimal maintenance strategy and optimal maintenance cost rate is analyzed.

Sequential imperfect preventive maintenance policy with random maintenance quality under reliability limit

2011 ◽  
Vol 225 (8) ◽  
pp. 1926-1935 ◽  
Author(s):  
Z Wang ◽  
J Yang ◽  
G Wang ◽  
G Zhang
Keyword(s):  
Failure Rate ◽  
Preventive Maintenance ◽  
Average Cost ◽  
Numerical Control ◽  
Maintenance Policy ◽  
Cost Rate ◽  
Proposed Model ◽  
Optimal Maintenance ◽  
Average Cost Rate ◽  
Optimal Maintenance Policy

To determine the optimal maintenance number for a system with random maintenance quality in infinite time horizon, a sequential imperfect preventive maintenance model considering reliability limit is proposed. The proposed model is derived from the combination of the Kijima type virtual age model and the failure rate adjustment model. Maintenance intervals of the proposed model are obtained through an iteration method when both failure rate increase factor and maintenance restoration factor are random variables with a uniform distribution. The optimal maintenance policy is presented by minimizing the long-run average cost rate. A real numerical example for the failures of numerical control equipment is given to demonstrate the proposed model. Finally, a discussion is presented to show how the optimal average cost rate depends on the different cost parameters. The results show that in order to satisfy the practical requirements of high reliability, it is necessary and worthwhile to consider the system's reliability limit in preventive maintenance practice.

scholarly journals Evaluasi Manajemen Perawatan dengan Metode Reliability Centered Maintenance (RCM) II pada Mesin Cane Cutter 1 dan 2 di Stasiun Gilingan PG Meritjan - Kediri

Rekayasa ◽  
2017 ◽  
Vol 10 (2) ◽  
pp. 99
Author(s):  
Cahyo Purnomo Prasetyo
Keyword(s):  
Maintenance Cost ◽  
Repair Cost ◽  
Maintenance Policy ◽  
Work Safety ◽  
Maintenance Costs ◽  
Reliability Centered Maintenance ◽  
Optimal Maintenance ◽  
Critical Components ◽  
Optimal Maintenance Policy ◽  
Production Target

<p>Penelitian ini bertujuan untuk menentukan kebijakan perawatan optimal yang dapat mengurangi biaya perbaikan (repair cost) dan biaya konsekwensi operasional (operational consequence cost). Metode yang diterapkan pada penelitian ini adalah Reliability Centered Maintenance (RCM) II. Penelitian ini difokuskan pada mesin Cane Cutter 1 dan 2 dengan pertimbangan beberapa aspek yaitu : pengaruh kegagalan terhadap pencapaian target produksi, resiko keselamatan kerja dan biaya perawatan yang akan ditimbulkan. Dari hasil penelitian dapat diketahui bahwa komponen kritis pada mesin Cane Cutter 1 dan 2 adalah : Pisau dan Baut Pisau. Perawatan yang dilakukan untuk mengantisipasi dan mengatasi kegagalan yang terjadi pada komponen mesin tersebut adalah proactive task yang meliputi : scheduled restoration task dan scheduled discard task. Rata-rata penurunan biaya perawatan total yang didapatkan dengan mengurangkan ‘biaya total pada interval perawatan awal’ dan ‘biaya total pada interval perawatan optimal’ adalah 14,82 %.</p><p>Kata Kunci: cane cutter, downtime, pabrik gula.</p><p><strong> </strong></p><p><strong>ABSTRACT</strong></p><p><em>This research aims to determine the optimal maintenance policy which could reduce repair cost and operational consequence cost. The methods which applied in this research is Reliability Centered Maintenance (RCM) II. This research focuses on Cane Cutter 1 and 2 machines by considering several aspects, such as and effect of any failure on production target achievement, work safety risk and maintenance cost which might be caused by the critical condition. The result showed that some critical components at the Cane Cutter 1 and 2 machines were : Blade and Blade Bolt. The maintenance which could be done to anticipate and deal with any failure occurring in the machine components was called proactive task comprising : scheduled restoration task and scheduled discard task. The average reduction in total maintenance costs which was obtained by subtracting ‘total costs at initial maintenance interval’ and ‘total costs at optimal maintenance interval’ amounted to 14,82 %.</em></p><p><em>Keywords: cane cutter, downtime, sugar factory</em></p>

scholarly journals Effectivness Of The Failure Rate On Maintenance Costs Of The City Buses

2015 ◽  
Vol 35 (1) ◽  
pp. 99-108
Author(s):  
Piotr Ignaciuk ◽  
Joanna Rymarz ◽  
Andrzej Niewczas
Keyword(s):  
Failure Rate ◽  
Cost Comparison ◽  
Maintenance Cost ◽  
Calendar Time ◽  
Maintenance Costs ◽  
Failure Index ◽  
Repair Costs ◽  
Maintenance Service ◽  
The City

Abstract The purpose of this paper was to present a failure rate and maintenance cost comparison for two types of city transport buses. The paper presents in detail a case study of well known bus brands used at Municipal Transport Company in Lublin. A failure index of all functional and constructional systems of the vehicles and their technical availability with regards to calendar time was determined. The paper also presents analysis of the factors related to maintenance costs of buses, including costs of fluids, repair costs and maintenance service. It has been demonstrated, that both analyzed buses generate similar maintenance costs, while their failures and technical availability differ significantly in operational practice. These differences are particularly evident in relation to the cumulative costs of repairs.

Optimal track geometry maintenance limits using machine learning: A case study

2020 ◽  
pp. 095440972097009
Author(s):  
Ahmad Kasraei ◽  
Jabbar Ali Zakeri ◽  
Arash Bakhtiary
Keyword(s):  
Clustering Algorithm ◽  
Cost Model ◽  
Maintenance Cost ◽  
Maintenance Costs ◽  
Corrective Maintenance ◽  
Track Geometry ◽  
Penalty Costs ◽  
Optimal Maintenance ◽  
Maintenance Activities ◽  
Maintenance Model

The aim of this study has been to determine the optimal maintenance limits for one of the main railway lines in Iran in such a way that the total maintenance costs are minimized. For this purpose, a cost model has been developed by considering costs related to preventive maintenance activities, corrective maintenance activities, inspection, and a penalty costs associated with exceeding corrective maintenance limit. Standard deviation of longitudinal level was used to measure the quality of track geometry. In order to reduce the level of uncertainty in the maintenance model, K-means clustering algorithm was used to classify track sections with most similarity. Then, a linear function was used for each cluster to model the degradation of track sections. Monte Carlo technique was used to simulate track geometry behavior and determine the optimal maintenance limit which minimizes the total maintenance costs. The results of this paper show that setting an optimal limit can affect total annual maintenance cost about 27 to 57 percent.

scholarly journals A Study on the Predictive Maintenance Method of Fully Mechanized Mining Equipment based on Cost and Time Factors

2021 ◽  
Author(s):  
Xiangang Cao ◽  
Tianbo Xu ◽  
Youjun Zhao ◽  
Jiangbin Zhao ◽  
Yan Wang
Keyword(s):  
Time Factors ◽  
Predictive Maintenance ◽  
Maintenance Cost ◽  
Maintenance Planning ◽  
Mining Equipment ◽  
Cost Rate ◽  
Maintenance Time ◽  
Maintenance Cycle ◽  
Optimal Maintenance ◽  
Single Objective

Abstract In view of the problems of excessive maintenance and insufficient utilization of equipment service life caused by preventive maintenance of fully mechanized mining equipment with fixed cycle, a predictive maintenance method is proposed. Firstly, based on Weibull distribution function and evolution rules of equipment decay, the evolution model of equipment failure rate is established; Then, the single-objective decision-making models of equipment maintenance cost rate and maintenance downtime rate are established respectively. On this basis, the multi-objective predictive maintenance planning model of fully mechanized mining equipment with comprehensive cost and time factors is established, and the optimal predictive maintenance cycle planning sequence is obtained. Combined with the coal production continuation plan, this paper puts forward a method to determine the optimal maintenance time by making suitable choices between advance maintenance and delay maintenance. The result confirms the effectiveness and superiority of the proposed method.

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