Integrated production, maintenance and quality control for complex manufacturing systems considering imperfect maintenance and dynamic inspection

Xiaotong Wei, Yalong Wang, Yingdong He, Zixian Liu and Zhen He

Reliability Engineering and System Safety, 2025, vol. 259, issue C

Abstract: In complex manufacturing systems, production equipment typically consists of numerous components. Such equipment is prone to high failure rates in the early stages of use owing to a combination of manufacturing defects, design defects, and improper initial setup. In formulating production, maintenance, and quality policies, most joint optimization models consider that equipment failure rates gradually increase with use time. However, they ignore failures that might occur in the early stages of equipment use, resulting in high quality costs. Considering manufacturing defects in the early use of complex manufacturing systems, this study formulates a new joint optimization model that aims to determine the safety stock level, production cycle length, preventive maintenance threshold, and inspection sampling ratio that minimize the expected unit cost of the system. First, we consider the equipment failure rate with a bathtub curve shape and develop a corresponding dynamic sampling strategy. Second, we divide the production process into six scenarios and develop a condition-based maintenance policy based on the degree of equipment deterioration, production time, and average output quality limits. We solve the model using Monte Carlo simulation and design of experiments. Sensitivity analysis and comparative study verify that the proposed strategy can flexibly adapt to production changes with fewer inspections and lower costs.

Keywords: Quality control; Complex manufacturing equipment; Bathtub curve; Dynamic inspection; Condition-based maintenance (search for similar items in EconPapers)
Date: 2025
References: Add references at CitEc
Citations:

Downloads: (external link)
http://www.sciencedirect.com/science/article/pii/S0951832025000997
Full text for ScienceDirect subscribers only

Related works:
This item may be available elsewhere in EconPapers: Search for items with the same title.

Export reference: BibTeX RIS (EndNote, ProCite, RefMan) HTML/Text

Persistent link: https://EconPapers.repec.org/RePEc:eee:reensy:v:259:y:2025:i:c:s0951832025000997

DOI: 10.1016/j.ress.2025.110896

Access Statistics for this article

Reliability Engineering and System Safety is currently edited by Carlos Guedes Soares

More articles in Reliability Engineering and System Safety from Elsevier
Bibliographic data for series maintained by Catherine Liu ().