Maintenance Strategy Choice Supported by the Failure Rate Function: Application in a Serial Manufacturing Line

Abstract

The purpose of this article is to choose a maintenance procedure for the critical equipment of a forging production line with five machines. The research method is quantitative modelling and simulation. The main research technique includes retrieving time between failure and time to repair data and find the most likely distribution that has produced the data. The most likely failure rate function helps to define the maintenance strategy. The study includes two kinds of maintenance policies, reactive and anticipatory. Reactive policies include emergency and corrective procedures. Anticipatory policies include predictive and preventive ones combined with a total productive maintenance management approach. The most suitable combination for the first three machines is emergency and corrective choice. For the other machines, a combination of total productive maintenance and a predictive approach is optimal. The study encompasses the case of a serial production manufacturing line and maximum likelihood estimation. The failure rate function defines a combination of strategies for each machine. In addition, the study calculates the individual and systemic mean time to failure, mean time to repair, availability, and the most likely number of failures per production order, which follows a Poisson process. The main contribution of the article is a structured method to help define maintenance choices for critical equipment based on empirical data.