Opportunistic maintenance of multi-equipment system: a case study

Rao, Abhishek; Bhadury, Bikash

doi:10.1002/1099-1638(200011/12)16:6<487::aid-qre353>3.0.co;2-q

Cited by 37 publications

(22 citation statements)

References 9 publications

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“…Compared with separate maintenance, the OM activities conducted when some units are repaired or replaced would lead to a very small additional cost for the set-up cost. With the introduction of OM, the other units' states should also be considered in one unit's maintenance decision-making process (Rao and Bhadhury, 2000). Dekker and Smeitink (1991) developed an opportunity-based block replacement model in which a component can only be replaced preventively at maintenance opportunities, and they derived a so-called one-opportunity-look-ahead replacement policy.…”

Section: Literature Reviewmentioning

confidence: 99%

Bottleneck-based opportunistic maintenance model for series production systems

Zhou

Shao

et al. 2015

Journal of Quality in Maintenance Engineering

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Purpose – The purpose of this paper is to develop a bottleneck-based opportunistic maintenance (OM) model for the series production systems with the integration of the imperfect effect into maintenance activities. Design/methodology/approach – On the analysis of availability and maintenance cost, preventive maintenance (PM) models subjected to imperfect maintenance for different equipment types are built. And then, a cost-saving function of OM is established to find out an optimal OM strategy, depending on whether the front-bottleneck machines adopt OM strategy or not. A numerical example is given to show how the proposed bottleneck-based OM model proceeded. Findings – The simulation results indicate that the proposed model is better than the methods to maintain the machines separately and the policy to maintain all machines when bottleneck machine reaches its reliability threshold. Furthermore, the relationship between OM strategy and corresponding parameters is identified through sensitivity analysis. Practical implications – In practical situations, the bottleneck machine always determines the throughput of the whole series production system. Whenever a PM activity is carried out on the bottleneck machine, there will be an opportunity to maintenance other machines. Under such circumstances, findings of this paper can be utilized for the determination of optimal OM policy with the objective of minimizing total maintenance cost of the system. Originality/value – This paper presents a bottleneck-based OM optimization model with the integration of the imperfect effect as a new method to schedule maintenance activities for a series production system with buffers. Furthermore, to the best of the knowledge, this paper presents the first attempt to considering the bottleneck constraint on system capacity and diverse types of machines as a means to minimize the maintenance cost and ensure the system throughput.

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Section: Literature Reviewmentioning

confidence: 99%

Bottleneck-based opportunistic maintenance model for series production systems

Zhou

Shao

et al. 2015

Journal of Quality in Maintenance Engineering

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“…Opportunistic maintenance is therefore not a maintenance policy for a single component but for a collection of components in a production line or plant. The concept of opportunistic maintenance is based on the economic dependency among the components (Rao and Bhadury 2000). Simultaneous maintenance actions are performed by proceeding with and/or postponing maintenance activities for individual components, which results in lower maintenance costs.…”

Section: Opportunistic Maintenancementioning

confidence: 99%

The influence of condition-based maintenance on workforce planning and maintenance scheduling

Koochaki

Bokhorst

Wortmann

et al. 2013

International Journal of Production Research

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Condition-based maintenance (CBM) is generally considered an attractive maintenance policy for a single component: it uses the operating condition of the component to predict a failure event and therefore tries to avoid any unplanned downtime and unnecessary maintenance activities. However, operations managers tend to be much more interested in optimising the performance of the entire asset-system, where the grouping of maintenance activities and the availability of maintenance workers may play a role. Therefore, this paper focuses on the impact of using either CBM or age-based replacement (ABR) in serial and parallel multicomponent systems (1) without worker constraints, (2) with a single internal maintenance worker, and (3) with external maintenance workers with a significant response time. With an internal maintenance worker, the sequential execution of maintenance activities prevents efficiency gains in the serial configuration and here CBM performs better. Also in the parallel configurations, the efficiency under CBM is generally better than under ABR. However, with external maintenance workers, CBM is not able to group maintenance activities as well as ABR, which results in a lower efficiency in the serial configuration. CBM performs better than ABR with respect to total maintenance costs, while ABR results in a smoother maintenance plan.

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“…Barata and Tong respectively established the maintenance optimization models for the production line using the different methods [12,13]. Rao et al [14] developed an opportunity maintenance model for the production line to conduct preventive maintenance on several machines at the same time when one of the machines in the production line breaks down. However, it is difficult to use the opportunity maintenance strategy for the complex production line consisting of many machines.…”

Section: Introductionmentioning

confidence: 99%

Development of a Preventive Maintenance Strategy for an Automatic Production Line Based on Group Maintenance Method

Zhang

et al. 2018

Applied Sciences

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The high maintenance costs and low reliability of automatic production line are attributed to the complexity of maintenance management. In the present study, a preventive maintenance strategy for the automatic production line was developed based on the group maintenance method. The criticality of machines in the production line was evaluated, and then the machines were classified into three groups: the most critical machines, the secondary critical machines and the general machines. The general machines were performed on the breakdown maintenance. The preventive maintenance model of the most critical machines was established with the shortest shutdown time as decision objective on basis of the Delay-time theory. The maintenance model of the secondary critical machine was established based on the considering of reliability-maintenance cost. A case study on an automotive part automatic production line was carried out to verify the proposed preventive maintenance strategy based on the production line data, and the maintenance periods of the most and secondary critical machines were gained; meanwhile, the machines all satisfied the reliability requirements during the maintenance periods.

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Opportunistic maintenance of multi-equipment system: a case study

Cited by 37 publications

References 9 publications

Bottleneck-based opportunistic maintenance model for series production systems

Bottleneck-based opportunistic maintenance model for series production systems

The influence of condition-based maintenance on workforce planning and maintenance scheduling

Development of a Preventive Maintenance Strategy for an Automatic Production Line Based on Group Maintenance Method

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