An Industrial Scenario-Based Approach to Integrating Maintenance and Quality Planning
This paper presents a novel industrial scenario-based approach to integrating maintenance and quality planning. First, a new preventive maintenance planning model is formed. Herein, to account for reality, different dependencies between the constituent components of a complex multi-component machine...
Saved in:
| Main Authors: | , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
IEEE
2024-01-01
|
| Series: | IEEE Access |
| Subjects: | |
| Online Access: | https://ieeexplore.ieee.org/document/10781383/ |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1846115001246416896 |
|---|---|
| author | Bhushan S. Purohit Amit Kumar Jain Bhupesh Kumar Lad |
| author_facet | Bhushan S. Purohit Amit Kumar Jain Bhupesh Kumar Lad |
| author_sort | Bhushan S. Purohit |
| collection | DOAJ |
| description | This paper presents a novel industrial scenario-based approach to integrating maintenance and quality planning. First, a new preventive maintenance planning model is formed. Herein, to account for reality, different dependencies between the constituent components of a complex multi-component machine are evaluated simultaneously, such as stochastic, structural, and economic. It also serves as a foundation for their complex mathematical formulation. Several potential failure modes in which these components can fail are exhibited. Additionally, the influence of such failures on multiple product quality aspects is well-thought-out in the modelling. Successively, we leverage the inter-dependencies between machine maintenance and product quality to build a realistic integrated plan, defying all existing model assumptions, such as a single critical to quality characteristics for part inspection; perfect machining and maintenance process; deterministic process time for manufacturing/maintenance/inspection, and many more. As a result, operation costs are optimised, including overlooked costs linked to detected and undetected rejects. Besides, a simulation-based optimisation algorithm is offered to overcome the integrated operations planning computing complexity. Making it more responsive in a dynamic industrial scenario perceived in digital cum intelligent enterprises. Finally, it is evaluated in a realistic shop floor scenario to expand the model’ s robustness and relevance. This revealed significant cost savings over existing fixed interval policies in an industrial scenario where machines are capital intensive, components are interdependent, machine failure modes are numerous, and various quality characteristics are affected by a failure of the machine. To conclude, the superiority of this approach is then generalised to a broad range of industrial environments. |
| format | Article |
| id | doaj-art-13b56e1585a64ca58be4b934cf8f9be5 |
| institution | Kabale University |
| issn | 2169-3536 |
| language | English |
| publishDate | 2024-01-01 |
| publisher | IEEE |
| record_format | Article |
| series | IEEE Access |
| spelling | doaj-art-13b56e1585a64ca58be4b934cf8f9be52024-12-20T00:01:09ZengIEEEIEEE Access2169-35362024-01-011219016919018510.1109/ACCESS.2024.351266710781383An Industrial Scenario-Based Approach to Integrating Maintenance and Quality PlanningBhushan S. Purohit0Amit Kumar Jain1https://orcid.org/0000-0001-7939-7810Bhupesh Kumar Lad2https://orcid.org/0000-0002-7828-0116Department of Mechanical Engineering, Industrial and Systems Engineering, Indian Institute of Technology Indore, Indore, Madhya Pradesh, IndiaDepartment of Mechanical Engineering, School of Computing, Engineering and Built Environment, Glasgow Caledonian University, Glasgow, U.K.Department of Mechanical Engineering, Industrial and Systems Engineering, Indian Institute of Technology Indore, Indore, Madhya Pradesh, IndiaThis paper presents a novel industrial scenario-based approach to integrating maintenance and quality planning. First, a new preventive maintenance planning model is formed. Herein, to account for reality, different dependencies between the constituent components of a complex multi-component machine are evaluated simultaneously, such as stochastic, structural, and economic. It also serves as a foundation for their complex mathematical formulation. Several potential failure modes in which these components can fail are exhibited. Additionally, the influence of such failures on multiple product quality aspects is well-thought-out in the modelling. Successively, we leverage the inter-dependencies between machine maintenance and product quality to build a realistic integrated plan, defying all existing model assumptions, such as a single critical to quality characteristics for part inspection; perfect machining and maintenance process; deterministic process time for manufacturing/maintenance/inspection, and many more. As a result, operation costs are optimised, including overlooked costs linked to detected and undetected rejects. Besides, a simulation-based optimisation algorithm is offered to overcome the integrated operations planning computing complexity. Making it more responsive in a dynamic industrial scenario perceived in digital cum intelligent enterprises. Finally, it is evaluated in a realistic shop floor scenario to expand the model’ s robustness and relevance. This revealed significant cost savings over existing fixed interval policies in an industrial scenario where machines are capital intensive, components are interdependent, machine failure modes are numerous, and various quality characteristics are affected by a failure of the machine. To conclude, the superiority of this approach is then generalised to a broad range of industrial environments.https://ieeexplore.ieee.org/document/10781383/Dependenciesintegrated operations planningmaintenancemulti-component machineoptimisationquality planning |
| spellingShingle | Bhushan S. Purohit Amit Kumar Jain Bhupesh Kumar Lad An Industrial Scenario-Based Approach to Integrating Maintenance and Quality Planning IEEE Access Dependencies integrated operations planning maintenance multi-component machine optimisation quality planning |
| title | An Industrial Scenario-Based Approach to Integrating Maintenance and Quality Planning |
| title_full | An Industrial Scenario-Based Approach to Integrating Maintenance and Quality Planning |
| title_fullStr | An Industrial Scenario-Based Approach to Integrating Maintenance and Quality Planning |
| title_full_unstemmed | An Industrial Scenario-Based Approach to Integrating Maintenance and Quality Planning |
| title_short | An Industrial Scenario-Based Approach to Integrating Maintenance and Quality Planning |
| title_sort | industrial scenario based approach to integrating maintenance and quality planning |
| topic | Dependencies integrated operations planning maintenance multi-component machine optimisation quality planning |
| url | https://ieeexplore.ieee.org/document/10781383/ |
| work_keys_str_mv | AT bhushanspurohit anindustrialscenariobasedapproachtointegratingmaintenanceandqualityplanning AT amitkumarjain anindustrialscenariobasedapproachtointegratingmaintenanceandqualityplanning AT bhupeshkumarlad anindustrialscenariobasedapproachtointegratingmaintenanceandqualityplanning AT bhushanspurohit industrialscenariobasedapproachtointegratingmaintenanceandqualityplanning AT amitkumarjain industrialscenariobasedapproachtointegratingmaintenanceandqualityplanning AT bhupeshkumarlad industrialscenariobasedapproachtointegratingmaintenanceandqualityplanning |