Energy-Oriented Maintenance Decision-Making for Sustainable Manufacturing Based on Energy Saving Window

Abstract

In recent years, the industry's responsibility to join in sustainable manufacturing becomes huge, while innovating sustainability has been a new trend. Industrial enterprises are pursuing energy reduction to meet future needs for sustainable globalization and government legislations for green manufacturing. To run a manufacturing line in an energy-efficient manner, an energy-oriented maintenance methodology is developed. At the machine layer, the multi-attribute model (MAM) method is extended by modeling the energy attribute. Preventive maintenance (PM) intervals of each machine are dynamically scheduled according to the machine deterioration, maintenance effects, and environmental conditions. At the system layer, a novel energy saving window (ESW) policy is proposed to reduce energy for the whole line. Energy consumption interactivities, batch production characteristics, and system-layer maintenance opportunities are comprehensively considered. Real-time choice of PM adjustments is scheduled by comparing the energy savings of advanced PM and delayed PM. The results prove the energy reduction achieved by this MAM-ESW methodology. It effectively utilizes standby power, reduces energy consumption, avoids manufacturing breakdown, and decreases scheduling complexity. Furthermore, this energy-oriented maintenance framework can be applied not only in the automotive industry but also for a broader range of manufacturing domains such as the aerospace, semiconductor, and chemical industries.