An energy-oriented maintenance policy under energy and quality constraints for a multielement-dependent degradation batch production system

Abstract In recent years, to attain a competitive edge, merely optimizing the production efficiency is no longer the whole story that the manufacturing enterprises concentrate on. Instead, the increasing energy costs are driving manufacturing enterprises to seek an energy-oriented approach further to improve the overall performance of the production systems. Therefore, an opportunistic maintenance policy under energy and quality constraints is developed for a degrading batch production system in this paper. First and foremost, the degradation process of the production system is modeled using the Levy-type processes, meanwhile, the concept of the multielement-dependent degradation model was first put forward to describe the energy and quality degradation in production systems during the work period. Secondly, the degradation constraint threshold, energy constraint threshold, and quality constraint threshold are developed to determine the maintenance groups which include the machines that require two types of maintenance, preventive and corrective. Subsequently, in order not to interrupt the batch production activities, the changeover time between every two batches is regarded as an energy saving window to perform maintenance actions for the integrated maintenance groups. Thirdly, an energy-oriented integrated model that optimizes the total cost rate in consideration of energy and quality is developed, and the optimal maintenance combination scheme can be obtained by the Monte Carlo method. Finally, a numerical example is used to prove the effectiveness of the proposed policy.