Risk-Based Maintenance Optimization of Production Tools in a Dynamic Environment

Flexible manufacturing systems use multi-tool machines to produce diverse products but pose maintenance challenges due to variable tool usage and conditions. Riskbased maintenance prioritizes activities based on risk, adapting strategies like preventive or reactive maintenance as needed. Traditional approaches of risk-based maintenance for complex systems is impractical for flexible manufacturing systems because frequent schedule changes require constant re-modeling. This study focuses on maintaining individual tools by performing a reliability analysis based on usage data. Using these data, a riskbased objective function combines maintenance and downtime costs to guide a population-based algorithm. The expected result is an risk-based maintenance model and an algorithm that optimize maintenance scheduling for individual tools in flexible manufacturing systems.