Industrial maintenance decision-making: A systematic literature review

Abstract The increasing competition among industries has leveraged the emergence of various tools and methods for maintenance decision-making support. This paper identifies in literature the application areas of industrial maintenance decision-making, the relationships between these areas and the ways in which authors integrate tools and methods. This information makes it possible to identify trends and deficiencies in this context, helping to centralize the efforts required for future work. This work follows a series of structured steps for a systematic literature review of papers related to the main topic available in online databases. The selected papers are subject to a content assessment and grouped according to the application areas. The direct comparison between these areas and the construction of a relational matrix provide a quantitative interpretation of the results and well-structured information. Additionally, this paper proposes a framework based on information from the literature, which summarizes the origin and flow of information used in the development of models, showing the relationship among application areas of decision making. The research undertaken identifies trends focused on joint production systems optimization and increasing the deployment of methods for autonomous equipment predictions.

[1]  A. Subash Babu,et al.  Integrated graphical model to evaluate multi-criteria maintenance policies for degradable systems , 2013, Int. J. Syst. Assur. Eng. Manag..

[2]  Timo Kärri,et al.  Modelling costs in maintenance networks , 2013 .

[3]  Mahesh D. Pandey,et al.  The probability distribution of maintenance cost of a system affected by the gamma process of degradation: Finite time solution , 2012, Reliab. Eng. Syst. Saf..

[4]  Joseph Mathew,et al.  Bearing fault prognosis based on health state probability estimation , 2012, Expert Syst. Appl..

[5]  Wenbin Wang,et al.  Condition-based maintenance of dynamic systems using online failure prognosis and belief rule base , 2012, Expert Syst. Appl..

[6]  Adiel Teixeira de Almeida,et al.  A Multicriteria Decision Model for Assessment of Failure Consequences in the RCM Approach , 2015 .

[7]  Dragan Banjevic,et al.  A myopic policy for optimal inspection scheduling for condition based maintenance , 2015, Reliab. Eng. Syst. Saf..

[8]  Pablo Viveros,et al.  Graphical Analysis for Operation Management: A Graphical Method to Support Operation Decision Making , 2016, Qual. Reliab. Eng. Int..

[9]  Cristiano Alexandre Virgínio Cavalcante,et al.  Opportunistic Maintenance Policy for a System with Hidden Failures: A Multicriteria Approach Applied to an Emergency Diesel Generator , 2014 .

[10]  M. Shinozuka,et al.  Planning structural inspection and maintenance policies via dynamic programming and Markov processes. Part II: POMDP implementation , 2014, Reliab. Eng. Syst. Saf..

[11]  Marco Tantardini,et al.  Integrated maintenance and production planning: a model to include rescheduling costs , 2012 .

[12]  Chase Rainwater,et al.  Selective Maintenance Decision-Making Over Extended Planning Horizons , 2009, IEEE Transactions on Reliability.

[13]  Jianchao Zeng,et al.  A general modeling method for opportunistic maintenance modeling of multi-unit systems , 2015, Reliab. Eng. Syst. Saf..

[14]  Mirka Kans,et al.  Common database for cost-effective improvement of maintenance performance , 2008 .

[15]  Kamran Shahanaghi,et al.  Determining maintenance system requirements by viewpoint of reliability and lean thinking: a MODM approach , 2010 .

[16]  N. Hritonenko,et al.  Economic life replacement under improving technology , 2011 .

[17]  Abdelhakim Artiba,et al.  To maintain or not to maintain? What should a risk-averse decision maker do? , 2005 .

[18]  Cher Ming Tan,et al.  Optimal maintenance strategy of deteriorating system under imperfect maintenance and inspection using mixed inspection scheduling , 2013, Reliab. Eng. Syst. Saf..

[19]  R. M. Chandima Ratnayake,et al.  Technical integrity management: measuring HSE awareness using AHP in selecting a maintenance strategy , 2010 .

[20]  Peter Funk,et al.  Agent‐based monitoring using case‐based reasoning for experience reuse and improved quality , 2009 .

[21]  Seungchul Lee,et al.  Joint decision making for maintenance and production scheduling of production systems , 2013 .

[22]  Enrico Zio,et al.  Predictive Maintenance by Risk Sensitive Particle Filtering , 2014, IEEE Transactions on Reliability.

[23]  Fang Liu,et al.  Statistically Planned and Individually Improved Predictive Maintenance Management for Continuously Monitored Degrading Systems , 2010, IEEE Transactions on Reliability.

[24]  Bernard Kamsu-Foguem,et al.  Graph-based reasoning in collaborative knowledge management for industrial maintenance , 2013, Comput. Ind..

[25]  Haitao Liao,et al.  Joint Production and Spare Part Inventory Control Strategy Driven by Condition Based Maintenance , 2010, IEEE Transactions on Reliability.

[26]  R. Jamshidi,et al.  Maintenance policy determination for a complex system consisting of series and cold standby system with multiple levels of maintenance action , 2015 .

[27]  Jianfeng Li,et al.  An evaluation of maintenance strategy using risk based inspection , 2011 .

[28]  Abdur Rahim,et al.  Practical implications of managerial decisions to integrate production scheduling and maintenance , 2015, Int. J. Syst. Assur. Eng. Manag..

[29]  Benoît Iung,et al.  PRM-based patterns for knowledge formalisation of industrial systems to support maintenance strategies assessment , 2013, Reliab. Eng. Syst. Saf..

[30]  Tangbin Xia,et al.  Operating load based real-time rolling grey forecasting for machine health prognosis in dynamic maintenance schedule , 2015, J. Intell. Manuf..

[31]  Naveen Chilamkurti,et al.  An ontology-based framework for process monitoring and maintenance in petroleum plant , 2013 .

[32]  Susanne Dienst,et al.  Integrated system for analyzing maintenance records in product improvement , 2015 .

[33]  Tullio Tolio,et al.  A virtual factory approach for in situ simulation to support production and maintenance planning , 2015 .

[34]  Wenxing Zhou,et al.  Optimal condition-based maintenance decisions for systems with dependent stochastic degradation of components , 2014, Reliab. Eng. Syst. Saf..

[35]  Tiedo Tinga,et al.  The adoption of prognostic technologies in maintenance decision making: a multiple case study , 2015 .

[36]  Ying Peng,et al.  Current status of machine prognostics in condition-based maintenance: a review , 2010 .

[37]  Adiel Teixeira de Almeida,et al.  A multi-criteria decision model to determine inspection intervals of condition monitoring based on delay time analysis , 2009, Reliab. Eng. Syst. Saf..

[38]  Fan Wu,et al.  A cost effective degradation-based maintenance strategy under imperfect repair , 2015, Reliab. Eng. Syst. Saf..

[39]  Ali Gharbi,et al.  Simultaneous control of production, repair/replacement and preventive maintenance of deteriorating manufacturing systems , 2011 .

[40]  Viliam Makis,et al.  An optimal condition-based maintenance policy for a degrading system subject to the competing risks of soft and hard failure , 2015, Comput. Ind. Eng..

[41]  Ming Jian Zuo,et al.  An integrated framework for online diagnostic and prognostic health monitoring using a multistate deterioration process , 2014, Reliab. Eng. Syst. Saf..

[42]  Xinyu Shao,et al.  A cost‐based selective maintenance decision‐making method for machining line , 2011, Qual. Reliab. Eng. Int..

[43]  Lin Ma,et al.  Maintenance optimisation of a multi-state series-parallel system considering economic dependence and state-dependent inspection intervals , 2012, Reliab. Eng. Syst. Saf..

[44]  Enrique Villa,et al.  Utility based maintenance analysis using a Random Sign censoring model , 2011, Reliab. Eng. Syst. Saf..

[45]  José Luis Duarte Ribeiro,et al.  Establishment of a maintenance plan based on quantitative analysis in the context of RCM in a JIT production scenario , 2014, Reliab. Eng. Syst. Saf..

[46]  Anders Skoogh,et al.  Planning of Maintenance Activities – A Current State Mapping in Industry☆ , 2015 .

[47]  Ali Gharbi,et al.  Production planning and repair/replacement switching policy for deteriorating manufacturing systems , 2011 .

[48]  Dah-Chuan Gong,et al.  The application of genetic algorithm in the development of preventive maintenance analytic model , 2007 .

[49]  Antoine Grall,et al.  Multi-level predictive maintenance for multi-component systems , 2015, Reliab. Eng. Syst. Saf..

[50]  Jussi K. Vaurio Importance measures in risk-informed decision making: Ranking, optimisation and configuration control , 2011, Reliab. Eng. Syst. Saf..

[51]  Bo-Suk Yang,et al.  Machine health prognostics using survival probability and support vector machine , 2011, Expert Syst. Appl..

[52]  Hadjadj Aoul Elias,et al.  Combined Anomalies Prediction Using the Bayesian Theory , 2012, Qual. Reliab. Eng. Int..

[53]  M. Ilangkumaran,et al.  Selection of maintenance policy for textile industry using hybrid multi‐criteria decision making approach , 2009 .

[54]  Pablo Viveros,et al.  The Graphical Analysis for Maintenance Management Method: A Quantitative Graphical Analysis to Support Maintenance Management Decision Making , 2013, Qual. Reliab. Eng. Int..

[55]  Viliam Makis,et al.  Optimal maintenance policy and residual life estimation for a slowly degrading system subject to condition monitoring , 2015, Reliab. Eng. Syst. Saf..

[56]  Ashutosh Tiwari,et al.  State of the art in simulation-based optimisation for maintenance systems , 2015, Comput. Ind. Eng..

[57]  Petr Byczanski,et al.  Effective computing algorithm for maintenance optimization of highly reliable systems , 2013, Reliab. Eng. Syst. Saf..

[58]  M. Ilangkumaran,et al.  Multi‐criteria decision‐making approach to evaluate optimum maintenance strategy in textile industry , 2008 .

[59]  Zhigang Tian,et al.  Condition based maintenance optimization considering multiple objectives , 2009, Journal of Intelligent Manufacturing.

[60]  Zhuoqi Zhang,et al.  Optimal maintenance policy for multi-component systems under Markovian environment changes , 2013, Expert Syst. Appl..

[61]  Antoine Grall,et al.  Online maintenance policy for a deteriorating system with random change of mode , 2007, Reliab. Eng. Syst. Saf..

[62]  Mitra Fouladirad,et al.  Assessment of a maintenance model for a multi-deteriorating mode system , 2010, Reliab. Eng. Syst. Saf..

[63]  Ling‐Huey Su,et al.  Flexible preventive maintenance planning for two parallel machines problem to minimize makespan , 2010 .

[64]  Jinji Gao,et al.  Study and application of Reliability-centered Maintenance considering Radical Maintenance , 2010 .

[65]  Jun Wu,et al.  Selection of optimum maintenance strategies based on a fuzzy analytic hierarchy process , 2007 .

[66]  Lin Ma,et al.  Prediction of system reliability for single component repair , 2007 .

[67]  Dag Eirik Nordgård,et al.  Application of Bayesian networks for risk analysis of MV air insulated switch operation , 2010, Reliab. Eng. Syst. Saf..

[68]  Hamid Reza Karimi,et al.  Observer-Based Robust Control for Hydraulic Velocity Control System , 2013 .

[69]  Nidhal Rezg,et al.  Optimal selective renewal policy for systems subject to propagated failures with global effect and failure isolation phenomena , 2013, Reliab. Eng. Syst. Saf..

[70]  Gilberto Francisco Martha de Souza,et al.  Risk-based decision making method for maintenance policy selection of thermal power plant equipment , 2010 .

[71]  Terje Aven,et al.  An approach to maintenance optimization where safety issues are important , 2010, Reliab. Eng. Syst. Saf..

[72]  Vasile Deac,et al.  The Modern Approach to Industrial Maintenance Management , 2010 .

[73]  Robert Pellerin,et al.  Simultaneous control of maintenance and production rates of a manufacturing system with defective products , 2012, J. Intell. Manuf..

[74]  Laine Mears,et al.  Condition based maintenance-systems integration and intelligence using Bayesian classification and sensor fusion , 2015, J. Intell. Manuf..

[75]  Athena Zitrou,et al.  Robustness of maintenance decisions: Uncertainty modelling and value of information , 2013, Reliab. Eng. Syst. Saf..

[76]  Geert-Jan van Houtum,et al.  Separate tools or tool kits:an exploratory study of engineers' preferences , 2010 .

[77]  Kun-Yung Lu,et al.  A real-time decision-making of maintenance using fuzzy agent , 2009, Expert Syst. Appl..

[78]  Pooja Sharma,et al.  System failure behavior and maintenance decision making using, RCA, FMEA and FM , 2010 .

[79]  Ana Sánchez,et al.  Addressing imperfect maintenance modelling uncertainty in unavailability and cost based optimization , 2009, Reliab. Eng. Syst. Saf..

[80]  Jhareswar Maiti,et al.  Modeling risk based maintenance using fuzzy analytic network process , 2012, Expert Syst. Appl..

[81]  Carlos Eduardo Pereira,et al.  A model-based approach for data integration to improve maintenance management by mixed reality , 2013, Comput. Ind..

[82]  Raj Iyer,et al.  Condition-based Maintenance and the product improvement process , 2010, Comput. Ind..

[83]  B. Vahdani,et al.  Extension of VIKOR method based on interval-valued fuzzy sets , 2010 .

[84]  Xiaojun Zhou,et al.  Dynamic maintenance decision-making for series-parallel manufacturing system based on MAM-MTW methodology , 2012, Eur. J. Oper. Res..

[85]  James Gao,et al.  Web-based Process Planning for Machine Tool Maintenance and Services , 2015 .

[86]  Olivier Roux,et al.  To appear in: International Journal of Production Economics www.elsevier.com/locate/ijpe , 2010 .

[87]  Mehdi Hosseinabadi Farahani,et al.  An integrated GA-DEA algorithm for determining the most effective maintenance policy for a k -out-of- n problem , 2013, Journal of Intelligent Manufacturing.

[88]  Jing Lin,et al.  Reliability analysis for preventive maintenance based on classical and Bayesian semi-parametric degradation approaches using locomotive wheel-sets as a case study , 2015, Reliab. Eng. Syst. Saf..

[89]  Shahrul Kamaruddin,et al.  MAINTENANCE POLICY SELECTION MODEL-A CASE STUDY IN THE PALM OIL INDUSTRY , 2014 .

[90]  Adiel Teixeira de Almeida,et al.  Multicriteria Model for Selection of Preventive Maintenance Intervals , 2012, Qual. Reliab. Eng. Int..

[91]  Viliam Makis,et al.  Joint optimal lot sizing and preventive maintenance policy for a production facility subject to condition monitoring , 2015 .

[92]  Mónica A. López-Campos,et al.  Modelling a maintenance management framework based on PAS 55 standard , 2011, Qual. Reliab. Eng. Int..

[93]  Luciana Hazin Alencar,et al.  PROMETHEE-ROC Model for Assessing the Readiness of Technology for Generating Energy , 2015 .

[94]  Soumaya Yacout,et al.  Accuracy and robustness of decision making techniques in condition based maintenance , 2009, Journal of Intelligent Manufacturing.

[95]  Uday Kumar,et al.  A vector-dissimilarity-based approach for multi-criteria decision making , 2013, Int. J. Syst. Assur. Eng. Manag..

[96]  Hyun-Woo Cho,et al.  Multivariate calibration for machine health monitoring: kernel partial least squares combined with variable selection , 2010 .

[97]  MaCarmen Carnero An evaluation system of the setting up of predictive maintenance programmes , 2006 .

[98]  Jing Zhou,et al.  Integrated reconfiguration and age-based preventive maintenance decision making , 2007 .

[99]  David Baglee,et al.  Can Equipment Failure Modes Support the Use of a Condition Based Maintenance Strategy , 2014 .

[100]  Jun Ni,et al.  Short-term decision support system for maintenance task prioritization , 2009 .

[101]  Sadi Assaf,et al.  Performance evaluation and benchmarking for maintenance decision making units at petrochemical corporation using a DEA model , 2015 .

[102]  Pooja Sharma,et al.  Integrated framework to optimize RAM and cost decisions in a process plant , 2012 .

[103]  Uday Kumar,et al.  Robust‐optimum multi‐attribute age‐based replacement policy , 2012 .

[104]  Martin Jacobsson,et al.  A computerised model to enhance the cost-effectiveness of production and maintenance dynamic decisions : A case study at Fiat , 2013 .

[105]  Shey-Huei Sheu,et al.  Optimal preventive maintenance and repair policies for multi-state systems , 2015, Reliab. Eng. Syst. Saf..

[106]  Phuc Do,et al.  Maintenance grouping for multi-component systems with availability constraints and limited maintenance teams , 2015, Reliab. Eng. Syst. Saf..

[107]  Ajit Srividya,et al.  FIS based selection of CM system design parameters from a multi-objective optimisation model using GA , 2011, Int. J. Syst. Assur. Eng. Manag..

[108]  Amir Khanlari,et al.  Prioritizing equipments for preventive maintenance (PM) activities using fuzzy rules , 2008, Comput. Ind. Eng..

[109]  Huifang Wang,et al.  Research on Multiobjective Group Decision-Making in Condition-Based Maintenance for Transmission and Transformation Equipment Based on D-S Evidence Theory , 2015, IEEE Transactions on Smart Grid.

[110]  Yifan Zhou,et al.  Joint optimization of maintenance, buffer, and spare parts for a production system , 2015 .

[111]  Sebastián Martorell,et al.  Ageing PSA incorporating effectiveness of maintenance and testing , 2015, Reliab. Eng. Syst. Saf..

[112]  Amir Abbas Shojaie,et al.  A data mining model to identify inefficient maintenance activities , 2013, Int. J. Syst. Assur. Eng. Manag..

[113]  Gang Niu,et al.  Machine condition prognosis based on sequential Monte Carlo method , 2010, Expert Syst. Appl..

[114]  Hong-Zhong Huang,et al.  Analysis of maintenance policies for finite life-cycle multi-state systems , 2010, Comput. Ind. Eng..

[115]  Vladimir Polotski,et al.  Production and maintenance planning for a failure-prone deteriorating manufacturing system: a hierarchical control approach , 2015 .

[116]  Jun Ni,et al.  Decision support systems for effective maintenance operations , 2012 .

[117]  Mustapha Nourelfath,et al.  Integrated spare parts logistics and operations planning for maintenance service providers , 2014 .

[118]  Marcantonio Catelani,et al.  Context awareness for maintenance decision making: A diagnosis and prognosis approach , 2015 .

[119]  F. Sgarbossa,et al.  Industrial maintenance policy development: A quantitative framework , 2014 .

[120]  Oleg Kapliński The Utility Theory in Maintenance and Repair Strategy , 2013 .

[121]  Abdul Hameed,et al.  A framework to estimate the risk-based shutdown interval for a processing plant , 2014 .

[122]  Michael Pecht,et al.  A probabilistic description scheme for rotating machinery health evaluation , 2010 .

[123]  Hong-Zhong Huang,et al.  A Data-Driven Approach to Selecting Imperfect Maintenance Models , 2012, IEEE Transactions on Reliability.

[124]  Benoît Iung,et al.  Industrial system knowledge formalization to aid decision making in maintenance strategies assessment , 2015, Eng. Appl. Artif. Intell..

[125]  Jan Lundberg,et al.  Economic model for maintenance decision: a case study for mill liners , 2012 .

[126]  David W. Coit,et al.  Reliability for systems of degrading components with distinct component shock sets , 2014, Reliab. Eng. Syst. Saf..

[127]  S. Jack Hu,et al.  Allocation of maintenance resources in mixed model assembly systems , 2013 .

[128]  A. T. de Almeida,et al.  A multi‐criteria decision‐aiding model using PROMETHEE III for preventive maintenance planning under uncertain conditions , 2007 .

[129]  María Carmen Carnero Multicriteria model for maintenance benchmarking , 2014 .

[130]  A. E. Haroun,et al.  Maintenance cost estimation: application of activity-based costing as a fair estimate method , 2015 .

[131]  Mitra Fouladirad,et al.  Condition-based inspection/replacement policies for non-monotone deteriorating systems with environmental covariates , 2010, Reliab. Eng. Syst. Saf..

[132]  Ana Sánchez,et al.  Maintenance modeling and optimization integrating human and material resources , 2010, Reliab. Eng. Syst. Saf..

[133]  Gregoris Mentzas,et al.  A proactive decision making framework for condition-based maintenance , 2015, Ind. Manag. Data Syst..

[134]  Karen Marais Value maximizing maintenance policies under general repair , 2013, Reliab. Eng. Syst. Saf..

[135]  Nils Boysen,et al.  Optimally locating in-house logistics areas to facilitate JIT-supply of mixed-model assembly lines , 2012 .

[136]  Marcello Braglia,et al.  AHP‐based evaluation of CMMS software , 2006 .

[137]  P. Baraldi,et al.  A Modeling Framework for Maintenance Optimization of Electrical Components Based on Fuzzy Logic and Effective Age , 2013, Qual. Reliab. Eng. Int..

[138]  Maroof A. Khan,et al.  Bayesian analysis of system availability with geometric failure law in life testing , 2010 .

[139]  Liliane Pintelon,et al.  A dynamic predictive maintenance policy for complex multi-component systems , 2013, Reliab. Eng. Syst. Saf..

[140]  Viliam Makis,et al.  Maximum Likelihood Estimation for a Hidden Semi-Markov Model with Multivariate Observations , 2012, Qual. Reliab. Eng. Int..

[141]  José Aguilar-Castro,et al.  Agents-based design for fault management systems in industrial processes , 2007, Comput. Ind..

[142]  Donghua Zhou,et al.  Joint optimization of preventive maintenance and inventory policies for multi-unit systems subject to deteriorating spare part inventory , 2015 .

[143]  Khac Tuan Huynh,et al.  Multi-Level Decision-Making for The Predictive Maintenance of $k$ -Out-of-$n$ :F Deteriorating Systems , 2015, IEEE Transactions on Reliability.

[144]  Aditya Parida,et al.  Study and analysis of maintenance performance indicators (MPIs) for LKAB: A case study , 2007 .

[145]  A. T. de Almeida,et al.  Decision theory in maintenance decision making , 1995 .

[146]  Soumaya Yacout,et al.  LAD-CBM; new data processing tool for diagnosis and prognosis in condition-based maintenance , 2012, J. Intell. Manuf..

[147]  Tao Tang,et al.  Risk-Based Predictive Maintenance for Safety-Critical Systems by Using Probabilistic Inference , 2013 .

[148]  D. Tranfield,et al.  Towards a Methodology for Developing Evidence-Informed Management Knowledge by Means of Systematic Review , 2003 .

[149]  Wenbin Wang,et al.  A joint spare part and maintenance inspection optimisation model using the Delay-Time concept , 2011, Reliab. Eng. Syst. Saf..

[150]  D. N. Prabhakar Murthy,et al.  Data management in maintenance outsourcing , 2015, Reliab. Eng. Syst. Saf..

[151]  David W. Coit,et al.  Establishment of the optimal time interval between periodic inspections for redundant systems , 2014, Reliab. Eng. Syst. Saf..

[152]  Arjan S. Dijkstra,et al.  Cost benefits of postponing time-based maintenance under lifetime distribution uncertainty , 2015, Reliab. Eng. Syst. Saf..

[153]  N. S. Arunraj,et al.  Risk-based maintenance policy selection using AHP and goal programming. , 2010 .

[154]  M. Pandey,et al.  Selective maintenance for binary systems using age-based imperfect repair model , 2012, 2012 International Conference on Quality, Reliability, Risk, Maintenance, and Safety Engineering.

[155]  Anusha Pai,et al.  Development and implementation of maintenance management module of enterprise resource planning in maintenance of power plant , 2014, Int. J. Syst. Assur. Eng. Manag..

[156]  Philippe Weber,et al.  Using probabilistic relational models for knowledge representation of production systems: A new approach to assessing maintenance strategies , 2012 .

[157]  M. Shinozuka,et al.  Planning structural inspection and maintenance policies via dynamic programming and Markov processes. Part I: Theory , 2014, Reliab. Eng. Syst. Saf..

[158]  Qi Gao,et al.  Maintenance interval decision models for a system with failure interaction , 2015 .

[159]  Subra Ganesan,et al.  Application of Statistical Techniques and Neural Networks in Condition‐Based Maintenance , 2013, Qual. Reliab. Eng. Int..

[160]  Benoît Iung,et al.  Maintenance alternative integration to prognosis process engineering , 2007 .