Predictive Maintenance and Upgrade Scheduling for Production Line under Multi-period Product-service Paradigm

In the rapidly developing product–service paradigm, a multi-unit manufacturing system will be leased many times during life cycle. Besides maintenance programming for a single leasing period, an upgrade policy is essential to achieve life-cycle profit optimization during sequential periods. This article presents a framework integrating opportunistic maintenance scheduling and upgrade decision for the leased system throughout its life cycle based on a real-time prognostic method. With machine-level prognosis updating, system-level opportunistic predictive maintenance is dynamically achieved by leasing profit-saving calculations during each leasing period. Between successive leasing contracts, the optimal upgrade levels are dynamically determined through upgrade profit-saving maximization. A numerical example of a leased manufacturing line demonstrates the long-term economic effectiveness of this policy. The proposed framework extends traditional opportunistic maintenance policies in both the machine-level prognosis and the system-level upgrade decision. This framework can be applied to a broad range of leased systems with longer service lifetimes.