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Abstract When maintenance resources in a manufacturing system are limited, a challenge arises in determining how to allocate these resources among multiple competing maintenance jobs. This work formulates an online prioritization problem to tackle this challenge using a Markov decision process (MDP) to model the system behavior and Monte Carlo tree search (MCTS) to seek optimal maintenance actions in various states of the system. Further, case-based reasoning (CBR) is adopted to retain and reuse search experience gathered from MCTS to reduce the computational effort needed over time and to improve decision-making efficiency. The proposed method results in increased system throughput when compared to existing methods of maintenance prioritization while also reducing the computation time needed to identify optimal maintenance actions as more information is gathered. This is especially beneficial in manufacturing settings where maintenance decisions must be made quickly to minimize the negative performance impact of machine downtime. 

Often in manufacturing systems, scenarios arise where the demand for maintenance exceeds the capacity of maintenance resources. This results in the problem of allocating the limited resources among machines competing for them. This maintenance scheduling problem can be formulated as a Markov decision process (MDP) with the goal of finding the optimal dynamic maintenance action given the current system state. However, as the system becomes more complex, solving an MDP suffers from the curse of dimensionality. To overcome this issue, we propose a two-stage approach that first optimizes a static condition-based maintenance (CBM) policy using a genetic algorithm (GA) and then improves the policy online via Monte Carlo tree search (MCTS). The static policy significantly reduces the state space of the online problem by allowing us to ignore machines that are not sufficiently degraded. Furthermore, we formulate MCTS to seek a maintenance schedule that maximizes the long-term production volume of the system to reconcile the conflict between maintenance and production objectives. We demonstrate that the resulting online policy is an improvement over the static CBM policy found by GA.