Condition-based maintenance optimization for batch production system based on demand fluctuations

Currently, independently considering maintenance in production cannot effectively resolve practical production issues and enhance reliability. Addressing equipment maintenance issues under the characteristics of fluctuations in market-oriented batch production order quantities, system operational continuity, and product quality stability, this paper proposes a condition-based maintenance for batch production system under demand fluctuation. First, the Gamma process is used to describe the aging levels of each device, and accelerated decay factors and improvement factors are introduced to reflect the characteristics of performance degradation and imperfect maintenance. Then, the production plan is updated on a rolling basis, per batch production cycle. To minimize expected maintenance costs, the timing of initial preventive maintenance for each device is determined, and maintenance strategies are dynamically adjusted based on cost changes caused by early or delayed maintenance. Finally, a case study validates the effectiveness of the proposed condition-based maintenance model for bath production systems under demand fluctuations. Sensitivity analysis demonstrates the impact of parameter changes on maintenance cycle, maintenance frequency and costs.