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research-article

Energy-oriented maintenance decision-making for sustainable manufacturing based on MAM-ESW methodology

[+] Author and Article Information
Tangbin Xia

Mem. ASME, State Key Laboratory of Mechanical System and Vibration, Department of Industrial Engineering, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
xtbxtb@sjtu.edu.cn

Lifeng Xi

State Key Laboratory of Mechanical System and Vibration, Department of Industrial Engineering, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
lfxi@sjtu.edu.cn

Shichang Du

State Key Laboratory of Mechanical System and Vibration, Department of Industrial Engineering, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
lovbin@sjtu.edu.cn

Lei Xiao

State Key Laboratory of Mechanical System and Vibration, Department of Industrial Engineering, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
leixiao211@sjtu.edu.cn

Ershun Pan

State Key Laboratory of Mechanical System and Vibration, Department of Industrial Engineering, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
pes@sjtu.edu.cn

1Corresponding author.

ASME doi:10.1115/1.4038996 History: Received June 01, 2017; Revised December 28, 2017

Abstract

In recent years, the industry's responsibility to join in sustainable manufacturing is huge, while innovating sustainability has become a new standard. Besides the classic object of cost reduction, industrial enterprises are pursuing energy reduction to meet future needs for sustainable globalization and government legislations for green manufacturing. To maintain manufacturing lines in an energy-effective manner, an energy-oriented maintenance methodology is developed. At the machine layer, the multi-attribute model (MAM) method is extended by modeling the energy attribute. Preventive maintenance (PM) intervals of different machines are dynamically scheduled according to machine deteriorations, maintenance effects and environmental conditions. At the system layer, a novel energy saving window (ESW) policy is proposed to save energy for the whole line. Energy consumption interactivities, batch production characteristics and system-layer maintenance opportunities are comprehensively considered. Real-time choice of PM adjustments is obtained by comparing the energy savings of Advanced PM and Delayed PM. This proposed methodology is demonstrated through the case study based on the collected reliability information from a production line of engine crankshaft. The results can effectively prove the energy effectiveness of the MAM-ESW methodology. The methodology efficiently utilizes standby power, saves energy consumption, avoids manufacturing breakdown and reduces scheduling complexity. Furthermore, this energy-oriented maintenance framework can be applied not only in the automotive industry, but also for a broader range of manufacturing domains such as aerospace, semiconductor and chemical industries.

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