Joint optimization of preventive maintenance and product quality improvement policies for deteriorating manufacturing systems with quality-reliability dependency

Ji Zhang, Xiaohui Chen, Youjun An, Lin Zhang, Haohao Shi and Weigang Xu

Reliability Engineering and System Safety, 2025, vol. 255, issue C

Abstract: Machine reliability and product quality are usually investigated independently in most traditional models. However, in the actual manufacturing process, machine reliability and product quality are commonly interdependent due to strong coupling between the machine and the product. In this paper, three joint optimization models for preventive maintenance (PM) and product quality improvement are developed for deteriorating manufacturing systems considering quality-reliability dependency. First, the degradation process of quality-related components (QRCs) is depicted by Gamma process, and product quality deviation is obtained by considering the quantitative relationship between the degradation of QRCs and product quality. Second, joint optimization policy of age-based maintenance and product quality improvement is proposed for deteriorating manufacturing systems with quality-reliability dependency. Third, above maintenance policy is extended to manufacturing systems processing jobs with random processing time, and then maintenance first (MF) and maintenance last (ML) policies are developed, respectively. Furthermore, we compare all of the maintenance models to determine which policy should be selected for manufacturing systems under specific conditions, and all theoretical discussions in this paper are analytically made. Finally, the effectiveness of the proposed joint policies is verified by a case study on a cylindrical gear housing machining process.

Keywords: Preventive maintenance; Product quality; Quality-reliability dependency; Random processing time; Multiple maintenance policies; Analytical solution (search for similar items in EconPapers)
Date: 2025
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Persistent link: https://EconPapers.repec.org/RePEc:eee:reensy:v:255:y:2025:i:c:s0951832024007324

DOI: 10.1016/j.ress.2024.110661

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