An Optimal Preventive Maintenance Model to Enhance Availability and Reliability of Flexible Manufacturing Systems

Document Type : Research Paper

Author

Faculty of Industrial and Systems Engineering, Tarbiat Modares University, Tehran, Iran

Abstract

General preventive maintenance model for the components of a system, which improves the reliability to ‘as good as new,’ was used to optimize the maintenance cost. The cost function of a maintenance policy was minimized under given availability constraint. On the other hand, in order to ensure appropriate reliability and availability, the development of the optimal maintenance policy is the one of the main issues in system to perform preventive maintenance (PM) in equipment. In this paper, maintenance characteristics of a typical flexible manufacturing system (FMS) have been determined. These characteristics can be used to understand and prevent the complex reality of failures and repairs. Also, an optimal model for the preventive maintenance management of a FMS has been presented based on preview literature in order to enhance availability and reliability of this system and to reduce the cost of maintenance tasks. Finally, proposed framework has been applied for a robot paint sprayer and its results shown in a form of the preventive maintenance plan, distribution fitting and Reliabilities’ parameters for each component s of robot paint sprayer, and the maintenance scheduling timetable.

Keywords

Main Subjects


AKS Jardine (1973). Maintenance replacement and reliability. Pitman Publishing, Toronto, Ontario.
Benjamin Lhorente, Diederik Lugtigheid, Peter F. Knights & Alejandro Santana (2004). "A model for optimal armature maintenance in electric haul truck wheel motors: a case study". Reliability Engineering & System Safety, 84(2), 209-218.
Bris, R., Chatelet, E., Yalaoui, F., 2003, New method to minimize the preventive maintenance cost of series –parallel systems. Reliability Engineering and System Safety, 82, 247–255.
Cho, D.I., Parlar, M., 1991, A survey of maintenance models for multi-unit systems. European Journal of Operational Research, 51, 1-23.
Duarte, J.A.C., Craveiro, J.C.T.A., Trigo, T.P., 2006, Optimization of the preventive maintenance plan of a series components system. International Journal of Pressure Vessels and Piping, 83, 244–248.
Fotsch, R.J., 1985, Machine tool justification policies: Their effect on productivity and profitability. Journal of Manufacturing Systems, 3 (2), 169-195.
Gits, C.W., 1986, On the maintenance concept for a technical system; II. Literature review. Maintenance Management International, 6 (3), 181-196.
Hammer, H., 1987, Availability, performance and service of FMS. The FMS Magazine, 5 (4), 180-186.
Koomsap, P., Shaikh, N.I., V. V. Prabhu, V.V., 2005, Integrated process control and condition-based maintenance scheduler for distributed manufacturing control systems. International Journal of Production Research, 43 (8), 1625 – 1641.
Lie, C.H., Hwang, C.L., Tillman, F.A., 1977, Availability of maintained systems: A state-of-the-art survey. AIIE Transactions, 9 (7), 247-259.
Luxhøj, J.T, Jens, J.O., Thorsteinsson, U., 1997, Trends and perspectives in industrial maintenance management, Journal of Manufacturing Systems, 16 (6), 437-453.
McCall, J.J., 1965, Maintenance policies for stochastically failing equipment: A survey. Management Science, 11, 493- 525.
Meredith, J.R., 1988, Installation of flexible manufacturing systems teaches management lessons in integration, labor, costs, and benefits. Industrial Engineering, 20 (4), 17-27.
Michael Vineyard, Kwasi Amoako-Gyampah & Jack R Meredith (1999). "Failure rate distributions for flexible manufacturing systems: An empirical study". European Journal of Operational Research, 116(1), 139-155.
Nada, O.A., EIMaraghy, H.A., EIMaraghy, W.H., 2006, Quality Prediction in Manufacturing System Design, Journal of Manufacturing Systems, 25 (3), 153-171.
Pintelon, L.M.A., Van Puyvelde, F.L.B., Gelders, L.F., 1995, An age-based replacement policy with non-zero repair times for a continuous production process. International Journal of Production Research, 33 (8), 2111-2123.
Sherif, Y.S., Smith, M.L., 1981, Optimal maintenance models or systems subject to failure: A review. Naval Research Logistics Quarterly, 28, 47-74.
Tsai, Y., Wang, K., Tsai, L., 2004, A study of availability-centered preventive maintenance for multi-component systems. Reliability Engineering and System Safety, 84, 261-270.
Yang, Z., Djurdjanovic, D. and Ni, J., 2007, Maintenance Scheduling for a Manufacturing System of Machines with Adjustable Throughput, IIE Transactions on Quality and Reliability Engineering, 39 (12), 1111-1125.
 Zhou, J., Djurdjanovic, D., Simmons-Ivy, J. and Ni, J. 2007, Integration of Maintenance and Reconfiguration Operations for Cost-Effective Maintenance in Reconfigurable Manufacturing Systems, IIE Transactions on Quality and Reliability Engineering, 39 (12), 1085-1102.