Many real-world systems experience deterioration with usage and age, which often leads to low product quality, high production cost, and low system availability. Most previous maintenance and reliability models in the literature do not incorporate condition monitoring information for decision making, which often results in poor failure prediction for partially observable deteriorating systems. For that reason, the development of fault prediction and control scheme using condition-based maintenance techniques has received considerable attention in recent years. This research presents a new framework for predicting failures of a partially observable deteriorating system using Bayesian control techniques. A time series model is fitted to a vector observation process representing partial information about the system state. Residuals are then calculated using the fitted model, which are indicative of system deterioration. The deterioration process is modeled as a 3-state continuous-time homogeneous Markov process. States 0 and 1 are not observable, representing healthy (good) and unhealthy (warning) system operational conditions, respectively. Only the failure state 2 is assumed to be observable. Preventive maintenance can be carried out at any sampling epoch, and corrective maintenance is carried out upon system failure. The form of the optimal control policy that maximizes the long-run expected average availability per unit time has been investigated. It has been proved that a control limit policy is optimal for decision making. The model parameters have been estimated using the Expectation Maximization (EM) algorithm. The optimal Bayesian fault prediction and control scheme, considering long-run average availability maximization along with a practical statistical constraint, has been proposed and compared with the age-based replacement policy. The optimal control limit and sampling interval are calculated in the semi-Markov decision process (SMDP) framework. Another Bayesian fault prediction and control scheme has been developed based on the average run length (ARL) criterion. Comparisons with traditional control charts are provided. Formulae for the mean residual life and the distribution function of system residual life have been derived in explicit forms as functions of a posterior probability statistic. The advantage of the Bayesian model over the well-known 2-parameter Weibull model in system residual life prediction is shown. The methodologies are illustrated using simulated data, real data obtained from the spectrometric analysis of oil samples collected from transmission units of heavy hauler trucks in the mining industry, and vibration data from a planetary gearbox machinery application.

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La maintenance prédictive joue un rôle important dans le maintien des systèmes de production continue car elle peut aider à réduire les interventions inutiles ainsi qu'à éviter des pannes imprévues. En effet, par rapport à la maintenance conditionnelle, la maintenance prédictive met en œuvre une étape supplémentaire, appelée le pronostic. Les opérations de maintenance sont planifiées sur la base de la prédiction des états de détérioration futurs et sur l'estimation de la vie résiduelle du système. Dans le cadre du projet européen FP7 SUPREME (Sustainable PREdictive Maintenance for manufacturing Equipment en Anglais), cette thèse se concentre sur le développement des modèles de détérioration stochastiques et sur des méthodes d'estimation de la vie résiduelle (Remaining Useful Life – RUL en anglais) associées pour les adapter aux cas d'application du projet. Plus précisément, les travaux présentés dans ce manuscrit sont divisés en deux parties principales. La première donne une étude détaillée des modèles de détérioration et des méthodes d'estimation de la RUL existant dans la littérature. En analysant leurs avantages et leurs inconvénients, une adaptation d’une approche de l'état de l'art est mise en œuvre sur des cas d'études issus du projet SUPREME et avec les données acquises à partir d’un banc d'essai développé pour le projet. Certains aspects pratiques de l’implémentation, à savoir la question de l'échange d'informations entre les partenaires du projet, sont également détaillées dans cette première partie. La deuxième partie est consacrée au développement de nouveaux modèles de détérioration et les méthodes d'estimation de la RUL qui permettent d'apporter des éléments de solutions aux problèmes de modélisation de détérioration et de prédiction de RUL soulevés dans le projet SUPREME. Plus précisément, pour surmonter le problème de la coexistence de plusieurs modes de détérioration, le concept des modèles « multi-branche » est proposé. Dans le cadre de cette thèse, deux catégories des modèles de type multi-branche sont présentées correspondant aux deux grands types de modélisation de l'état de santé des système, discret ou continu. Dans le cas discret, en se basant sur des modèles markoviens, deux modèles nommés Mb-HMM and Mb-HsMM (Multi-branch Hidden (semi-)Markov Model en anglais) sont présentés. Alors que dans le cas des états continus, les systèmes linéaires à sauts markoviens (JMLS) sont mis en œuvre. Pour chaque modèle, un cadre à deux phases est implémenté pour accomplir à la fois les tâches de diagnostic et de pronostic. A travers des simulations numériques, nous montrons que les modèles de type multi-branche peuvent donner des meilleures performances pour l'estimation de la RUL par rapport à celles obtenues par des modèles standards mais « mono-branche ». / Predictive maintenance plays a crucial role in maintaining continuous production systems since it can help to reduce unnecessary intervention actions and avoid unplanned breakdowns. Indeed, compared to the widely used condition-based maintenance (CBM), the predictive maintenance implements an additional prognostics stage. The maintenance actions are then planned based on the prediction of future deterioration states and residual life of the system. In the framework of the European FP7 project SUPREME (Sustainable PREdictive Maintenance for manufacturing Equipment), this thesis concentrates on the development of stochastic deterioration models and the associated remaining useful life (RUL) estimation methods in order to be adapted in the project application cases. Specifically, the thesis research work is divided in two main parts. The first one gives a comprehensive review of the deterioration models and RUL estimation methods existing in the literature. By analyzing their advantages and disadvantages, an adaption of the state of the art approaches is then implemented for the problem considered in the SUPREME project and for the data acquired from a project's test bench. Some practical implementation aspects, such as the issue of delivering the proper RUL information to the maintenance decision module are also detailed in this part. The second part is dedicated to the development of innovative contributions beyond the state-of-the-are in order to develop enhanced deterioration models and RUL estimation methods to solve original prognostics issues raised in the SUPREME project. Specifically, to overcome the co-existence problem of several deterioration modes, the concept of the "multi-branch" models is introduced. It refers to the deterioration models consisting of different branches in which each one represent a deterioration mode. In the framework of this thesis, two multi-branch model types are presented corresponding to the discrete and continuous cases of the systems' health state. In the discrete case, the so-called Multi-branch Hidden Markov Model (Mb-HMM) and the Multi-branch Hidden semi-Markov model (Mb-HsMM) are constructed based on the Markov and semi-Markov models. Concerning the continuous health state case, the Jump Markov Linear System (JMLS) is implemented. For each model, a two-phase framework is carried out for both the diagnostics and prognostics purposes. Through numerical simulations and a case study, we show that the multi-branch models can help to take into account the co-existence problem of multiple deterioration modes, and hence give better performances in RUL estimation compared to the ones obtained by standard "single branch" models.