Integrating machine learning techniques into optimal maintenance scheduling

Poor maintenance regimes often contribute to unplanned downtimes, quality defects and accidents; thus it is crucial to apply an effective maintenance strategy to achieve efficient and safe processes. Industry 4.0 has brought about a proliferation of digital data and with it new opportunities to advance and improve the way maintenance activities are planned. Here, we propose a novel methodology that utilises machine learning to predict both machine faults and repair time, and uses this data to underpin the scheduling of maintenance activities. This can be used to plan maintenance, and optimise the schedule with a cost objective within the constraints of labour availability and plant layout. When applied to a dataset obtained using a simulated Fischertechnik (FT) model, this methodology reduced the overall plant maintenance costs by decreasing unplanned downtimes and increasing maintenance efficiency. This work provides a promising first step towards improving the way maintenance tasks are approached in Industry 4.0.