DSF Core: Integrated Decision Support for Optimal Scheduling of Lifetime Extension Strategies for Industrial Equipment

This paper proposes a generic algorithm for industries with degrading and/or failing equipment with significant consequences. Based on the specifications and the real-time status of the production line, the algorithm provides decision support to machinery operators and manufacturers about the appropriate lifetime extension strategies to apply, the optimal time-frame for the implementation of each and the relevant machine components. The relevant recommendations of the algorithm are selected by comparing smartly chosen alternatives after simulation-based life cycle evaluation of Key Performance Indicators (KPIs), considering the short-term and long-term impact of decisions on these economic and environmental KPIs. This algorithm requires various inputs, some of which may be calculated by third-party algorithms, so it may be viewed as the ultimate algorithm of an overall Decision Support Framework (DSF). Thus, it is called “DSF Core”. The algorithm was applied successfully to three heterogeneous industrial pilots. The results indicate that compared to the lightest possible corrective strategy application policy, following the optimal preventive strategy application policy proposed by this algorithm can reduce the KPI penalties due to stops (i.e., failures and strategies) and production inefficiency by 30–40%.