A dynamic inspection model for predictive maintenance considering different degrees of inspection quality

Duc-Hanh Dinh, Phuc Do, Minh-Hien Bui and Phuoc-Vinh Dang

Reliability Engineering and System Safety, 2025, vol. 261, issue C

Abstract: In predictive maintenance (PdM), inspection plays a key role since it provides information about system health to support maintenance decision-making. However, inspection may be costly, which is one of the bottlenecks of the PdM. To reduce the overall inspection cost, this paper proposes a dynamic inspection model that incorporates three levels of inspection quality: (1) Binary state inspection, which is the cheapest one, can only reveal the binary state of the system, whether functioning or not; (2) Imperfect degradation inspection, which incurs a higher cost, but can provide the system state and degradation level with uncertainty; and (3) Perfect degradation inspection, which is the most expensive one, can provide the true system’s degradation level. Accordingly, at each inspection epoch, the inspection level is selected based on the predictive reliability of the system. By dynamically selecting the inspection level at each inspection epoch, the overall inspection cost of the system can be reduced. In that way, a reliability prediction model considering three kinds of inspections is first proposed for inspection and maintenance decision-making. Then, a maintenance cost model is developed to find the optimal predictive inspection and maintenance policy. Finally, a case study on predictive maintenance of an injection molding machine is conducted to investigate the applicability and benefit of the proposed dynamic inspection model.

Keywords: Dynamic inspection; Predictive maintenance; Multi-type inspection; Maintenance optimization (search for similar items in EconPapers)
Date: 2025
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Persistent link: https://EconPapers.repec.org/RePEc:eee:reensy:v:261:y:2025:i:c:s0951832025003667

DOI: 10.1016/j.ress.2025.111165

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