To address product quality degradation, reduced maintenance efficiency and delayed spare parts supply caused by system deterioration, a coordinated optimization method integrating quality monitoring, maintenance planning and spare parts ordering is proposed to reduce operational costs and improve system stability.
Based on delay-time theory, a coupled model is established to describe the relationship between system degradation and product quality, with defect stages refined into minor and severe levels. To manage supply uncertainty, a dual-mode spare parts ordering strategy combining regular and emergency modes is designed. Discrete-event simulation and response surface methodology are employed to jointly optimize inspection intervals, quality thresholds and ordering thresholds, aiming to minimize the system’s average cost rate.
Simulation results indicate that the proposed strategy outperforms traditional models in both cost control and system reliability. Compared with models that neglect quality or adopt a single-mode ordering strategy, the proposed method reduces the average daily cost by approximately 0.0787 thousand yuan/day and 0.0424 thousand yuan/day, demonstrating better economic performance and flexibility. Sensitivity analysis further confirms that maintenance costs, inspection frequency and defect-related losses significantly affect the optimization outcomes.
The study is limited by its focus on a single device, overlooking constraints such as manpower and material availability. This simplification may not fully capture the complexities of multi-unit systems, limiting the generalizability of the results to more dynamic and larger-scale industrial environments.
This research has significant practical implications in industries where system reliability is crucial. By integrating maintenance scheduling, quality monitoring and spare parts ordering into a unified optimization strategy, it provides industries with a cost-effective solution that reduces downtime, minimizes maintenance costs and enhances product quality. This integrated approach can be applied to various industrial systems, including manufacturing plants and power generation facilities.
The findings of this study can contribute to broader economic and environmental benefits by improving operational efficiency in industrial sectors. Reducing maintenance costs and preventing unnecessary downtime can lead to more sustainable practices in production systems. Moreover, the integration of product quality monitoring can help in minimizing defective products, thereby enhancing consumer satisfaction and trust in industrial goods.
This study incorporates product quality variation into the joint decision framework for maintenance and spare parts ordering. A defect rate–driven degradation modeling approach and a dual-mode ordering strategy are introduced. A unified optimization model integrating maintenance, quality monitoring and spare parts management is developed, offering a practical and cost-effective solution for industrial systems.
