Mission reliability-centered opportunistic maintenance approach for multistate manufacturing systems

Reliability-centered maintenance (RCM) is proactive maintenance that ensures the safe and economical operation of manufacturing systems. Previous studies on RCM for manufacturing systems based on basic reliability ignore the operational characteristics and functional requirements of a manufacturing system. Opportunistic maintenance can reasonably arrange maintenance scheduling and allocate maintenance resources. Therefore, this paper proposes a mission reliability-centered opportunistic maintenance optimization model for multistate manufacturing systems to realize the optimal combination of maintenance activities of multistate manufacturing systems. First, the failure mechanism caused by two types of quality defects of multistate manufacturing systems is expounded. A novel mission reliability connotation is proposed on the basis of the aforementioned mechanism, and the mission reliability-centered opportunistic maintenance principle is explained. Second, a mission reliability evaluation model is introduced to predict the actual operational state of manufacturing systems based on quantitative analysis of physical and functional failures. This model considers the relationship between production tasks, machine degradation, and product quality. Third, an opportunistic maintenance model for multistate manufacturing systems is proposed on the basis of mission reliability analysis, and the optimal maintenance strategy is obtained. Finally, the subway flow receiver manufacturing system is adopted to verify the effectiveness of the proposed approach.