Selection of Maintenance Strategies for Machines in a Series-Parallel System

Abstract

In this paper, an assessment of the failure frequency of machines in a series-parallel structure was conducted. The analyses contain the decomposition of the system according to the general theory of complex systems. Based on the results obtained, a model for an optimal determination of the mean time to failure (MTTF) according to the expected value of the gamma distribution was proposed. For this purpose, the method of moments was used to determine the optimal values of the parameters of the estimated gamma distribution. The article is designed to be analytical. The object of consideration in this analysis is the real production system working in accordance with make-to-order, with a high degree of product customisation. Moreover, in the considered system occurs a dichotomy of mutually exclusive flows: push and pull. In the article, the main emphasis was placed on the applicability of the proposed MTTF value-shaping algorithm. Then, the maintenance strategy for each machine (reactive, preventive or predictive) was proposed. Maintenance strategy selection considered sustainable development principles in the criterion of minimizing maintenance actions, fulfilling the assumption of not interrupting the flow of the processed material. Based on inductive analyses, the concepts of improvement actions individually for each machine in the analysed subsystem were deductively defined. As a result, it was proved that a reactive maintenance strategy is appropriate for machines that have manufacturing reserves and are low priority. The equipment possessing manufacturing reserves but also having an impact on the risk of interrupting the flow of the processed material should be operated in accordance with a preventive maintenance strategy. A predictive maintenance strategy was proposed for the machines with the highest priority, which simultaneously do not have manufacturing reserves and the risk of manufacturing line operation interruption is high. The considerations were conducted with a holistic approach, taking into account the main functional areas of the enterprise.