A Prescriptive Maintenance Framework for Textile Machinery Enabled by Hybrid Machine Learning and Multi-Objective Optimization

The textile industry faces machinery maintenance challenges due to reactive practices, lack of real-time monitoring, and absent integrated management systems, resulting in unplanned downtime, elevated costs, and quality variability. This study addresses these limitations by proposing a hybrid predictive–prescriptive framework integrating XGBoost 3.2.0 and LSTM models with a multi-objective optimization engine to generate data-driven maintenance recommendations. The framework was validated on four critical components, needles, hooks, needle guides, and thread tensioners, using operational data from a textile plant (November 2024–January 2026). Plant-wide Mean Time Between Failures increased by 38% (15–21 to 24–28 h), while Mean Time To Repair decreased by 15% (5.31 to 4.6 h). These improvements yielded 5.5% lower maintenance costs, 9% less fabric waste, and reduced cost per operating hour from $25 to $23.5. The prescriptive module transformed imperfect predictions into robust decisions by evaluating interventions against production constraints, spare parts availability, and risk criteria. Beyond quantitative gains, the framework enabled sustainable practices including data-driven spare parts policies and condition-based inspections. This work demonstrates that integrating prediction with prescription effectively overcomes structural maintenance challenges in textile manufacturing, providing a replicable methodology for broader industrial adoption.