Condition-based maintenance optimization for multi-component systems in mass production considering customer satisfaction

When multiple orders with different requirements must be fulfilled under limited capacity, order selection and maintenance planning for multi-component systems become strongly interdependent. To address this problem, this study proposes a condition-based maintenance strategy for multi-component systems and a joint optimization model for multi-order batch production that incorporates customer satisfaction. First, the deterioration trend of each component is described using the proportional hazards model, and the health status of each component is represented by virtual age. Different maintenance modes are then determined according to real-time monitoring results and maintenance thresholds after the completion of each production batch. With profit maximization as the objective, the condition-based maintenance strategy is integrated with a capacitated batch production model and a customer satisfaction model to develop a joint optimization framework for maintenance and multi-order production. Finally, the model is solved using simulated annealing and particle swarm optimization. A case study is used to verify the effectiveness of the proposed approach and to demonstrate its practical relevance, and a sensitivity analysis of the key model parameters is also conducted.