Performance evaluation of IIoT-based smart manufacturing systems under machine-feedstock-environment coupled degradation

Abstract

A fully automated production line suddenly halts—not because of a catastrophic breakdown, but due to the subtle interplay of equipment degradation, fluctuating feedstock quality, and environmental conditions. These factors collectively accumulate and eventually trigger random outages before the designed service life. This isn’t just complexity but is a phenomenon we term “coupled degradation cascading effect,” where micro-disturbances silently propagate and are amplified. In this paper, we decode this cascade with a novel performance framework that integrates the machine-feedstock-environment coupled degradation cascading effect in IIoT-based smart manufacturing systems (SMSs). By analyzing this multi-factor coupled degradation cascading process, we develop a coupled degradation model to quantify the machine failure probability after the accumulation and amplification of incremental damage. In addition, various operation and maintenance (O&M) activities are incorporated to mitigate the adverse impacts of such coupled degradation. We further propose two performance metrics—product-oriented performance efficiency (PEP) and order-oriented performance efficiency (PEO)—to enable a more realistic and comprehensive assessment of system performance. A case study of a flexible job shop manufacturing system for high-voltage electrical apparatus demonstrates that the median life of machines under machine-feedstock-environment coupled degradation falls short of their designed median life. The proposed methodology also reveals the practical implications of the machine-feedstock-environment coupled degradation, highlighting its influence on machine reliability, system O&M status, and the overall performance efficiency of SMSs. The insights revealed in this study will change how you design, manage, and evaluate SMSs in the Industry 4.0 era.

Graphical abstract

Keywords

smart manufacturing systems / machine-feedstock-environment coupled degradation / performance / operation and maintenance / quality management

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