Effective machine lifespan management using determined state–action cost estimation for multi-dimensional cost function optimization

This study introduces a comprehensive framework designed to enhance production efficiency by integrating maintenance strategies, energy costs, and production specifications. This integration is achieved through a novel empirical method for estimating state–action costs, suitable for both machines with measurable and non-measurable states-of-health. We address the challenge of under-determination in state–action cost optimization by employing a k-means clustering approach, ensuring robustness and applicability. Utilizing an adapted SARSA algorithm, our framework optimally controls shop-floor machinery to minimize the global cost function. The efficacy of the state–action cost estimation method is validated using NASA’s C-MAPSS dataset. Additionally, the optimization strategy is further corroborated through its successful implementation in an autonomous mining cart model on the shop floor. Our results highlight the framework’s ability to optimize machine lifetime and production processes effectively, providing tailored solutions that adapt to varying operational conditions without depending on predefined machine degradation models and costs.