Research On Shop Floor Energy Consumption Oriented Maintenance Scheduling System

Energy has been considered as the essential resource, which is the key to futureeconomical growth. The rapid population growth, resource reduction and energyshortage are increasingly important as the economics mushrooms in China. It, therefore,urges China to no longer take the reckless energy usage in return of such economicgrowth. Manufacturing enterprises, the major consumer of energy, should take theresponsibility for environment melioration. The research of equipment maintenanceshould change the role to accommodate with the sustainable manufacturing system. Inother word, the energy consumption should be considered as one new criterion forequipment maintenance. In order to reduce the energy consumption of facilities whilstmaintaining the high utility of facility, this paper proposes a shop floor energyconsumption oriented maintenance scheduling methodology, in which the energyconsumption is considered as the factor for assessment of facility reuse, overhaul anddisposal. Moreover, such methodology could assist to energy reduction of facility undercertain facility utilization rate, which contributes to new research area of maintenanceunder new circumstance of sustainable manufacturing.Firstly, this paper builds an energy oriented maintenance model for maintenancedecision making of production system, utilizing reliability function to model thedegradation process of facility. The maintenance actions are defined as minimal repair,medium repair, overhaul and replacement. Meanwhile, the Malik proportional agereduction model is presented as the maintenance effect of such maintenance actions.Artificial Neural Network (ANN) is used to form the mapping model of facility functionand energy consumption.Further, based on aforementioned models, two maintenance policies-the reliabilitycentered maintenance policy and energy considered maintenance policy-are introduced.Based on the fact of manufacturing process and the feature of facility and its subsystem,this paper introduces the attributes of facility-degradation, energy usage andmaintenance ability, and relative evaluation method to assess such attributes ofsubsystems. A Fisher algorithm based classification method is proposed to sort differentpolicies. The policy of subsystem would be obtained after trained algorithm classifiesthe attributes of subsystem.Artificial Immune Algorithm with Antibody Clone Algorithm is introduced. Theutilization of this Artificial Immune Algorithm is presented in terms of encoding,crossover operator, mutation operator, affinity function, density function and stimulantfunction. After that, this algorithm is used in solving the maintenance schedulingproblem. The sliding bearing manufacturing system is designed to introduce theapplication of the proposed methodology. Results and conclusions are further discussed. Finally, this paper elaborates the procedure of intelligent maintenance andmanagement system design Visual Basic6.0is utilized for interface development. TheActiveX is then used as the interfacing technology in order to call Matlab functionsunder the circumstance of Visual Basic6.0. The development of intelligent maintenanceand management system is then achieved as its three submodules are set up，namelydecision making of maintenance policy module, energy prediction module and shopfloor maintenance scheduling module.