A review of condition-based maintenance: Its prognostic and operational aspects
Yanrong LI, Shizhe PENG, Yanting LI, Wei JIANG
A review of condition-based maintenance: Its prognostic and operational aspects
Condition-based maintenance (CBM) detects early signs of failure and dictates when maintenance should be performed based on the actual condition of a system. In this paper, we first review some of the recent research on CBM under various physical structures and signal data. Then, we summarize several kinds of prognostic models that use monitoring information to estimate the reliability of complex systems or products. Monitoring information also facilitates operational decisions in production planning, spare parts management, reliability improvement, and prognostics and health management. Finally, we suggest some research opportunities for the reliability and operations management communities to fill the research gap between these two fields.
condition-based maintenance / prognostics / operational decision-making / reliability
[1] |
Aizpurua J I, Catterson V M, Papadopoulos Y, Chiacchio F, D’Urso D (2017). Supporting group maintenance through prognostics-enhanced dynamic dependability prediction. Reliability Engineering & System Safety, 168: 171–188
CrossRef
Google scholar
|
[2] |
Alaswad S, Xiang Y (2017). A review on condition-based maintenance optimization models for stochastically deteriorating system. Reliability Engineering & System Safety, 157: 54–63
CrossRef
Google scholar
|
[3] |
Armstrong M J, Atkins D R (1996). Joint optimization of maintenance and inventory policies for a simple system. IIE Transactions, 28(5): 415–424
CrossRef
Google scholar
|
[4] |
Aronis K P, Magou I, Dekker R, Tagaras G (2004). Inventory control of spare parts using a Bayesian approach: A case study. European Journal of Operational Research, 154(3): 730–739
CrossRef
Google scholar
|
[5] |
Attardi L, Guida M, Pulcini G (2005). A mixed-Weibull regression model for the analysis of automotive warranty data. Reliability Engineering & System Safety, 87(2): 265–273
CrossRef
Google scholar
|
[6] |
Bae S J, Mun B M, Chang W, Vidakovic B (2019). Condition monitoring of a steam turbine generator using wavelet spectrum based control chart. Reliability Engineering & System Safety, 184: 13–20
CrossRef
Google scholar
|
[7] |
Bahria N, Chelbi A, Bouchriha H, Dridi I H (2019). Integrated production, statistical process control, and maintenance policy for unreliable manufacturing systems. International Journal of Production Research, 57(8): 2548–2570
CrossRef
Google scholar
|
[8] |
Batun S, Maillart L M (2012). Reassessing tradeoffs inherent to simultaneous maintenance and production planning. Production and Operations Management, 21(2): 396–403
CrossRef
Google scholar
|
[9] |
Berrade M D, Scarf P A, Cavalcante C A (2018). Conditional inspection and maintenance of a system with two interacting components. European Journal of Operational Research, 268(2): 533–544
CrossRef
Google scholar
|
[10] |
Byon E, Ding Y (2010). Season-dependent condition-based maintenance for a wind turbine using a partially observed Markov decision process. IEEE Transactions on Power Systems, 25(4): 1823–1834
CrossRef
Google scholar
|
[11] |
Chehade A, Bonk S, Liu K (2017). Sensory-based failure threshold estimation for remaining useful life prediction. IEEE Transactions on Reliability, 66(3): 939–949
CrossRef
Google scholar
|
[12] |
Cheng G Q, Zhou B H, Li L (2018). Integrated production, quality control and condition-based maintenance for imperfect production systems. Reliability Engineering & System Safety, 175: 251–264
CrossRef
Google scholar
|
[13] |
Cinlar E, Bazant Z P, Osman E M (1977). Stochastic process for extrapolating concrete creep. ACSE Journal of the Engineering Mechanics Division, 103(6): 1069–1088
|
[14] |
Cipollini F, Oneto L, Coraddu A, Murphy A J, Anguita D (2018). Condition-based maintenance of naval propulsion systems: Data analysis with minimal feedback. Reliability Engineering & System Safety, 177: 12–23
CrossRef
Google scholar
|
[15] |
de Jonge B (2019). Discretizing continuous-time continuous-state deterioration processes, with an application to condition-based maintenance optimization. Reliability Engineering & System Safety, 188: 1–5
CrossRef
Google scholar
|
[16] |
de Jonge B, Scarf P A (2020). A review on maintenance optimization. European Journal of Operational Research, 285(3): 805–824
CrossRef
Google scholar
|
[17] |
Do P, Assaf R, Scarf P, Iung B (2019). Modelling and application of condition-based maintenance for a two-component system with stochastic and economic dependencies. Reliability Engineering & System Safety, 182: 86–97
CrossRef
Google scholar
|
[18] |
Ellingwood B R, Mori Y (1993). Probabilistic methods for condition assessment and life prediction of concrete structure in nuclear power plants. Nuclear Engineering and Design, 142(2–3): 155–166
CrossRef
Google scholar
|
[19] |
Elwany A H, Gebraeel N Z (2008). Sensor-driven prognostic models for equipment replacement and spare parts inventory. IIE Transactions, 40(7): 629–639
CrossRef
Google scholar
|
[20] |
Feng Q, Bi X, Zhao X, Chen Y, Sun B (2017). Heuristic hybrid game approach for fleet condition-based maintenance planning. Reliability Engineering & System Safety, 157: 166–176
CrossRef
Google scholar
|
[21] |
Fitouhi M C, Nourelfath M, Gershwin S B (2017). Performance evaluation of a two-machine line with a finite buffer and condition-based maintenance. Reliability Engineering & System Safety, 166: 61–72
CrossRef
Google scholar
|
[22] |
Ghamlouch H, Fouladirad M, Grall A (2017). The use of real option in condition-based maintenance scheduling for wind turbines with production and deterioration uncertainties. Reliability Engineering & System Safety, 188: 614–623
|
[23] |
Gössinger R, Helmke H, Kaluzny M (2017). Condition-based release of maintenance jobs in a decentralised production-maintenance system—An analysis of alternative stochastic approaches. International Journal of Production Economics, 193: 528–537
CrossRef
Google scholar
|
[24] |
Hanachi H, Mechefske C, Liu J, Banerjee A, Chen Y (2018). Performance-based gas turbine health monitoring, diagnostics, and prognostics: A survey. IEEE Transactions on Reliability, 67(3): 1340–1363
CrossRef
Google scholar
|
[25] |
Harris F W (1990). How many parts to make at once. Operations Research, 38(6): 947–950
CrossRef
Google scholar
|
[26] |
He Y, Gu C, Chen Z, Han X (2017). Integrated predictive maintenance strategy for manufacturing systems by combining quality control and mission reliability analysis. International Journal of Production Research, 55(19): 5841–5862
CrossRef
Google scholar
|
[27] |
Huang Y S, Huang C D, Ho J W (2017). A customized two-dimensional extended warranty with preventive maintenance. European Journal of Operational Research, 257(3): 971–978
CrossRef
Google scholar
|
[28] |
Huynh K T (2020). Modeling past-dependent partial repairs for condition-based maintenance of continuously deteriorating systems. European Journal of Operational Research, 280(1): 152–163
CrossRef
Google scholar
|
[29] |
Huynh K T, Grall A, Bérenguer C (2017). Assessment of diagnostic and prognostic condition indices for efficient and robust maintenance decision-making of systems subject to stress corrosion cracking. Reliability Engineering & System Safety, 159: 237–254
CrossRef
Google scholar
|
[30] |
Jafari L, Makis V (2015). Joint optimal lot sizing and preventive maintenance policy for a production facility subject to condition monitoring. International Journal of Production Economics, 169: 156–168
CrossRef
Google scholar
|
[31] |
Jafari L, Makis V (2016). Optimal lot-sizing and maintenance policy for a partially observable production system. Computers & Industrial Engineering, 93: 88–98
CrossRef
Google scholar
|
[32] |
Jafari L, Makis V (2019). Optimal production and maintenance policy for a partially observable production system with stochastic demand. International Journal of Industrial and Systems Engineering, 13(7): 449–456
|
[33] |
Jahani S, Kontar R, Zhou S Y, Veeramani D (2020). Remaining useful life prediction based on degradation signals using monotonic B-splines with infinite support. IISE Transactions, 52(5): 537–554
CrossRef
Google scholar
|
[34] |
Kazaz B, Sloan T W (2008). Production policies under deteriorating process conditions. IIE Transactions, 40(3): 187–205
CrossRef
Google scholar
|
[35] |
Khatab A, Diallo C, Aghezzaf E H, Venkatadri U (2019). Integrated production quality and condition-based maintenance optimisation for a stochastically deteriorating manufacturing system. International Journal of Production Research, 57(8): 2480–2497
CrossRef
Google scholar
|
[36] |
Kian R, Bektaş T, Ouelhadj D (2019). Optimal spare parts management for vessel maintenance scheduling. Annals of Operations Research, 272(1–2): 323–353
CrossRef
Pubmed
Google scholar
|
[37] |
Kim H, Kim J T, Heo G (2018). Failure rate updates using condition-based prognostics in probabilistic safety assessments. Reliability Engineering & System Safety, 175: 225–233
CrossRef
Google scholar
|
[38] |
Kim M, Song C, Liu K (2019). A generic health index approach for multisensor degradation modeling and sensor selection. IEEE Transactions on Automation Science and Engineering, 16(3): 1426–1437
CrossRef
Google scholar
|
[39] |
Kim M J, Makis V (2013). Joint optimization of sampling and control of partially observable failing systems. Operations Research, 61(3): 777–790
CrossRef
Google scholar
|
[40] |
Kontar R, Zhou S, Sankavaram C, Du X, Zhang Y (2018). Nonparametric-condition-based remaining useful life prediction incorporating external factors. IEEE Transactions on Reliability, 67(1): 41–52
CrossRef
Google scholar
|
[41] |
Kurt M, Kharoufeh J P (2010). Monotone optimal replacement policies for a Markovian deteriorating system in a controllable environment. Operations Research Letters, 38(4): 273–279
CrossRef
Google scholar
|
[42] |
Lam J Y J, Banjevic D (2015). A myopic policy for optimal inspection scheduling for condition based maintenance. Reliability Engineering & System Safety, 144: 1–11
CrossRef
Google scholar
|
[43] |
Lee J, Wu F, Zhao W, Ghaffari M, Liao L, Siegel D (2014). Prognostics and health management design for rotary machinery systems— Reviews, methodology and applications. Mechanical Systems and Signal Processing, 42(1–2): 314–334
CrossRef
Google scholar
|
[44] |
Lee M L T, Whitmore G A (2006). Threshold regression for survival analysis: Modeling event times by a stochastic process reaching a boundary. Statistical Science, 21(4): 501–513
CrossRef
Google scholar
|
[45] |
Levitin G, Xing L, Dai Y (2017). Preventive replacements in real-time standby systems with periodic backups. IEEE Transactions on Reliability, 66(3): 771–782
CrossRef
Google scholar
|
[46] |
Li R, Ryan J K (2011). A Bayesian inventory model using real-time condition monitoring information. Production and Operations Management, 20(5): 754–771
CrossRef
Google scholar
|
[47] |
Li Y, Chang Q, Biller S, Xiao G (2014). Event-based modelling of distributed sensor networks in battery manufacturing. International Journal of Production Research, 52(14): 4239–4252
CrossRef
Google scholar
|
[48] |
Li Y, Tang Q, Chang Q, Brundage M P (2017). An event-based analysis of condition-based maintenance decision-making in multistage production systems. International Journal of Production Research, 55(16): 4753–4764
CrossRef
Google scholar
|
[49] |
Lin L, Luo B, Zhong S S (2018). Multi-objective decision-making model based on CBM for an aircraft fleet with reliability constraint. International Journal of Production Research, 56(14): 4831–4848
CrossRef
Google scholar
|
[50] |
Lin X, Basten R J I, Kranenburg A A, van Houtum G J (2017). Condition based spare parts supply. Reliability Engineering & System Safety, 168: 240–248
CrossRef
Google scholar
|
[51] |
Liu B, Liang Z, Parlikad A K, Xie M, Kuo W (2017a). Condition-based maintenance for systems with aging and cumulative damage based on proportional hazards model. Reliability Engineering & System Safety, 168: 200–209
CrossRef
Google scholar
|
[52] |
Liu B, Wu S, Xie M, Kuo W (2017b). A condition-based maintenance policy for degrading systems with age- and state-dependent operating cost. European Journal of Operational Research, 263(3): 879–887
CrossRef
Google scholar
|
[53] |
Liu Q M, Dong M, Lv W Y, Ye C M (2019). Manufacturing system maintenance based on dynamic programming model with prognostics information. Journal of Intelligent Manufacturing, 30(3): 1155–1173
CrossRef
Google scholar
|
[54] |
Liu X, Li J, Al-Khalifa K N, Hamouda A S, Coit D W, Elsayed E A (2013). Condition-based maintenance for continuously monitored degrading systems with multiple failure modes. IIE Transactions, 45(4): 422–435
CrossRef
Google scholar
|
[55] |
Louit D, Pascual R, Banjevic D, Jardine A K (2011). Condition-based spares ordering for critical components. Mechanical Systems and Signal Processing, 25(5): 1837–1848
CrossRef
Google scholar
|
[56] |
Ma X Y, Liu B, Yang L, Peng R, Zhang X D (2020). Reliability analysis and condition-based maintenance optimization for a warm standby cooling system. Reliability Engineering & System Safety, 193: 106588
CrossRef
Google scholar
|
[57] |
Makis V, Jiang X (2003). Optimal replacement under partial observations. Mathematics of Operations Research, 28(2): 382–394
CrossRef
Google scholar
|
[58] |
Olde Keizer M C A, Flapper S D P, Teunter R H (2017a). Condition-based maintenance policies for systems with multiple dependent components: A review. European Journal of Operational Research, 261(2): 405–420
CrossRef
Google scholar
|
[59] |
Olde Keizer M C A, Teunter R H, Veldman J (2017b). Joint condition-based maintenance and inventory optimization for systems with multiple components. European Journal of Operational Research, 257(1): 209–222
CrossRef
Google scholar
|
[60] |
Olde Keizer M C A, Teunter R H, Veldman J, Babai M Z (2018). Condition-based maintenance for systems with economic dependence and load sharing. International Journal of Production Economics, 195: 319–327
CrossRef
Google scholar
|
[61] |
Peng C Y, Tseng S T (2009). Mis-specification analysis of linear degradation models. IEEE Transactions on Reliability, 58(3): 444–455
CrossRef
Google scholar
|
[62] |
Peng H, van Houtum G J (2016). Joint optimization of condition-based maintenance and production lot-sizing. European Journal of Operational Research, 253(1): 94–107
CrossRef
Google scholar
|
[63] |
Poppe J, Boute R N, Lambrecht M R (2018). A hybrid condition-based maintenance policy for continuously monitored components with two degradation thresholds. European Journal of Operational Research, 268(2): 515–532
CrossRef
Google scholar
|
[64] |
Shi H, Zeng J (2016). Real-time prediction of remaining useful life and preventive opportunistic maintenance strategy for multi-component systems considering stochastic dependence. Computers & Industrial Engineering, 93(3): 192–204
CrossRef
Google scholar
|
[65] |
Si X, Li T, Zhang Q, Hu X (2018). An optimal condition-based replacement method for systems with observed degradation signals. IEEE Transactions on Reliability, 67(3): 1281–1293
CrossRef
Google scholar
|
[66] |
Si X S, Wang W, Hu C H, Zhou D H (2011). Remaining useful life estimation—A review on the statistical data driven approaches. European Journal of Operational Research, 213(1): 1–14
CrossRef
Google scholar
|
[67] |
Skordilis E, Moghaddass R (2017). A condition monitoring approach for real-time monitoring of degrading systems using Kalman filter and logistic regression. International Journal of Production Research, 55(19): 5579–5596
CrossRef
Google scholar
|
[68] |
Sloan T W, Shanthikumar J G (2000). Combined production and maintenance scheduling for a multiple-product, single-machine production system. Production and Operations Management, 9(4): 379–399
CrossRef
Google scholar
|
[69] |
Song C, Liu K (2018). Statistical degradation modeling and prognostics of multiple sensor signals via data fusion: A composite health index approach. IISE Transactions, 50(10): 853–867
CrossRef
Google scholar
|
[70] |
Song C, Liu K, Zhang X (2019). A generic framework for multisensor degradation modeling based on supervised classification and failure surface. IISE Transactions, 51(11): 1288–1302
CrossRef
Google scholar
|
[71] |
Tang S, Guo X, Zhou Z (2014). Mis-specification analysis of linear Wiener process-based degradation models for the remaining useful life estimation. Proceedings of the Institution of Mechanical Engineers, Part O: Journal of Risk and Reliability, 228(5): 478–487
|
[72] |
Topan E, Tan T, van Houtum G J, Dekker R (2018). Using imperfect advance demand information in lost-sales inventory systems with the option of returning inventory. IISE Transactions, 50(3): 246–264
CrossRef
Google scholar
|
[73] |
uit het Broek M A J, Teunter R H, de Jonge B, Veldman J, van Foreest N D (2019). Condition-based production planning: Adjusting production rates to balance output and failure risk. Manufacturing & Service Operations Management. In press, doi: 10.1287/msom.2019.0773
|
[74] |
Verbert K, de Schutter B, Babuška R (2018). A multiple-model reliability prediction approach for condition-based maintenance. IEEE Transactions on Reliability, 67(3): 1364–1376
CrossRef
Google scholar
|
[75] |
Vogl G W, Weiss B A, Helu M (2016). A review of diagnostic and prognostic capabilities and best practices for manufacturing. Journal of Intelligent Manufacturing, 30(1): 79–95
Pubmed
|
[76] |
Walter G, Flapper S D (2017). Condition-based maintenance for complex systems based on current component status and Bayesian updating of component reliability. Reliability Engineering & System Safety, 168: 227–239
CrossRef
Google scholar
|
[77] |
Wan Q, Liu C, Wu Y, Zhou W (2018). A TBE control chart-based maintenance policy for a service facility. Computers & Industrial Engineering, 126: 136–148
CrossRef
Google scholar
|
[78] |
Wang H K, Huang H Z, Li Y F, Yang Y J (2016). Condition-based maintenance with scheduling threshold and maintenance threshold. IEEE Transactions on Reliability, 65(2): 513–524
CrossRef
Google scholar
|
[79] |
Wang L, Lu Z Q, Ren Y F (2019). A rolling horizon approach for production planning and condition-based maintenance under uncertain demand. Proceedings of the Institution of Mechanical Engineers, Part O: Journal of Risk and Reliability, 233(6): 1014–1028
|
[80] |
Wang W (2007). A two-stage prognosis model in condition based maintenance. European Journal of Operational Research, 182(3): 1177–1187
CrossRef
Google scholar
|
[81] |
Wang W, Christer A H (2000). Towards a general condition based maintenance model for a stochastic dynamic system. Journal of the Operational Research Society, 51(2): 145–155
CrossRef
Google scholar
|
[82] |
Wang X, Xu D (2010). An inverse Gaussian process model for degradation data. Technometrics, 52(2): 188–197
CrossRef
Google scholar
|
[83] |
Wei G, Zhao X, He S, He Z (2019). Reliability modeling with condition-based maintenance for binary-state deteriorating systems considering zoned shock effects. Computers & Industrial Engineering, 130: 282–297
CrossRef
Google scholar
|
[84] |
Wu J, Deng C, Shao X Y, Xie S Q (2009). A reliability assessment method based on support vector machines for CNC equipment. Science in China Series E: Technological Sciences, 52(7): 1849–1857
CrossRef
Google scholar
|
[85] |
Wu S (2014). Construction of asymmetric copulas and its application in two-dimensional reliability modelling. European Journal of Operational Research, 238(2): 476–485
CrossRef
Google scholar
|
[86] |
Xu W, Wang W (2013). RUL estimation using an adaptive inverse Gaussian model. Chemical Engineering Transactions, 33: 331–336
|
[87] |
Yahyatabar A, Najafi A A (2018). Condition based maintenance policy for series-parallel systems through proportional hazards model: A multi-stage stochastic programming approach. Computers & Industrial Engineering, 126: 30–46
CrossRef
Google scholar
|
[88] |
Yan T, Lei Y G, Wang B, Han T Y, Si X S, Li N P (2020). Joint maintenance and spare parts inventory optimization for multi-unit systems considering imperfect maintenance actions. Reliability Engineering & System Safety, 202: 106994
CrossRef
Google scholar
|
[89] |
Ye Z S, Chen N (2014). The inverse Gaussian process as a degradation model. Technometrics, 56(3): 302–311
CrossRef
Google scholar
|
[90] |
Ye Z S, Murthy D N P (2016). Warranty menu design for a two-dimensional warranty. Reliability Engineering & System Safety, 155: 21–29
CrossRef
Google scholar
|
[91] |
Zhang J X, Hu C H, He X, Si X S, Liu Y, Zhou D H (2017). Lifetime prognostics for deteriorating systems with time-varying random jumps. Reliability Engineering & System Safety, 167: 338–350
CrossRef
Google scholar
|
[92] |
Zhang M, Revie M (2017). Continuous-observation partially observable semi-Markov decision processes for machine maintenance. IEEE Transactions on Reliability, 66(1): 202–218
CrossRef
Google scholar
|
[93] |
Zhang N, Fouladirad M, Barros A, Zhang J (2020). Condition-based maintenance for a k-out-of-n, deteriorating system under periodic inspection with failure dependence. European Journal of Operational Research, 287(1): 159–167
CrossRef
Google scholar
|
[94] |
Zhang X, Zeng J (2017). Joint optimization of condition-based opportunistic maintenance and spare parts provisioning policy in multiunit systems. European Journal of Operational Research, 262(2): 479–498
CrossRef
Google scholar
|
[95] |
Zhang Z, Si X, Hu C, Lei Y (2018). Degradation data analysis and remaining useful life estimation: A review on Wiener-process-based methods. European Journal of Operational Research, 271(3): 775–796
CrossRef
Google scholar
|
[96] |
Zhao S, Makis V, Chen S, Li Y (2018a). Evaluation of reliability function and mean residual life for degrading systems subject to condition monitoring and random failure. IEEE Transactions on Reliability, 67(1): 13–25
CrossRef
Google scholar
|
[97] |
Zhao X, He S, He Z, Xie M (2018b). Optimal condition-based maintenance policy with delay for systems subject to competing failures under continuous monitoring. Computers & Industrial Engineering, 124: 535–544
CrossRef
Google scholar
|
[98] |
Zhou X, Xi L, Lee J (2007). Reliability-centered predictive maintenance scheduling for a continuously monitored system subject to degradation. Reliability Engineering & System Safety, 92(4): 530–534
CrossRef
Google scholar
|
[99] |
Zhou Z J, Hu C H, Xu D L, Chen M Y, Zhou D H (2010). A model for real-time failure prognosis based on hidden Markov model and belief rule base. European Journal of Operational Research, 207(1): 269–283
CrossRef
Google scholar
|
[100] |
Zhu S, van Jaarsveld W, Dekker R (2020). Spare parts inventory control based on maintenance planning. Reliability Engineering & System Safety, 193: 106600
CrossRef
Google scholar
|
/
〈 | 〉 |