Integrated maintenance and control policy based on quality control (original) (raw)
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This paper deals with the control of corrective and preventive maintenance rates in the production planning of a manufacturing system with machines subject to random failures and repairs. The introduction of preventive and corrective maintenance will increase the availability of the production system which guarantees the improvement of the system's productivity if the production planning is well done. The objective of this study is to minimize a discounted overall cost consisting of maintenance cost, inventory holding and backlog cost. The decision variables are the production, the machine preventive and repair rates which influence the inventory levels and the system capacity respectively. In the proposed model, the failure rate of a machine depends on its age; hence, the corrective and preventive maintenance policies are machine-age dependent. A computational algorithm, based on numerical methods, is used for solving the optimal control problem. Finally, a numerical example and a sensitive analysis are presented to illustrate the usefulness of the proposed approach. The structure of the optimal control policy is presented and extensions to more complex manufacturing systems are discussed.
International Journal of Production Research, 2009
In this paper, we develop a joint quality control and preventive maintenance policy for a randomly failing production system producing conforming and nonconforming units. The considered system consists of one machine designed to fulfil a constant demand. According to the proportion l of non conforming units observed on each lot and compared to a threshold value l m , one decides to undertake or not maintenance actions on the system. In order to palliate perturbations caused by the stopping of the machine to undergo preventive maintenance or an overhaul, a buffer stock h is built up to ensure the continuous supply of the subsequent production line. A mathematical model is developed and combined with simulation in order to determine simultaneously the optimal rate, l * m and the optimal size h * which minimize the expected total cost per time unit including the average costs related to maintenance, quality and inventory.
European Journal of Operational …, 2009
This paper compares two strategies for operating a production system composed of two machines working in parallel and a downstream inventory supplying an assembly line. The two machines, which are prone to random failures, undergo preventive and corrective maintenance operations. These operations with a random duration make the machines unavailable. Moreover, during regular subcontracting operations, one of these machines becomes unavailable to supply the downstream inventory. In the first strategy it is assumed that the periodicity of preventive maintenance operations and the production rate of each machine are independent. The second strategy suggests an interaction between the periods of unavailability and the production rates of the two machines in order to minimize production losses during these periods. A simulation model for each strategy is developed so as to be able to compare them and to simultaneously determine the timing of preventive maintenance on each machine considering the total average cost per time unit as the performance criterion. The second strategy is then considered, and a multi-criteria analysis is adopted to reach the best cost-availability compromise.
International Journal of Industrial Engineering Computations, 2017
In a continuous manufacturing environment where production and consumption occur simultaneously, one of the biggest challenges is the efficient management of production and inventory system. In order to manage the integrated production inventory system economically it is necessary to identify the optimal production time and the optimal production reorder point that either maximize the profit or minimize the cost. In addition, during production the process has to go through some natural phenomena like random breakdown of machine, deterioration of product over time, uncertainty in repair time that eventually create the possibility of shortage. In this situation, efficient management of inventory & production is crucial. This paper addresses the situation where a perishable (deteriorated) product is manufactured and consumed simultaneously, the demand of this product is stable over the time, machine that produce the product also face random failure and the time to repair this machine is also uncertain. In order to describe this scenario more appropriately, the continuously reviewed Economic Production Quantity (EPQ) model is considered in this research work. The main goal is to identify the optimal production uptime and the production reorder point that ultimately minimize the expected value of total cost consisting of machine setup, deterioration, inventory holding, shortage and corrective maintenance cost.
Production control of unreliable manufacturing systems producing defective items
Journal of Quality in Maintenance Engineering, 2011
Purpose -This paper seeks to address the production control problem of a failure-prone manufacturing system producing a random fraction of defective items. Design/methodology/approach -A fluid model with perfectly mixed good and defective parts has been proposed. This approach combines the descriptive capacities of continuous/discrete event simulation models with analytical models, experimental design, and regression analysis. The main objective of the paper is to extend the Bielecki and Kumar theory, appearing under the title "Optimality of zero-inventory policies for unreliable manufacturing systems", under which the machine considered produced only good quality items, to the case where the items produced are systematically a mixture of good as well as defective items.
International Journal of Production Economics, 2011
This paper presents a method to find the optimal production, repair/replacement and preventive maintenance policies for a degraded manufacturing system. The system is subject to random machine failures and repairs. The status of the system is considered to degrade with repair activities. When a failure occurs, the machine is either repaired or replaced. A replacement action renews the machine while a repair action brings it to a degraded operational state for which the next repair time increases as the number of repairs increases. A preventive maintenance action is considered to improve the reliability of the machine and therefore the disruptions caused by the machine failures are reduced. The decision variables are the production rate, the preventive maintenance rate and the repair/replacement switching policy upon machine failure. The objective of the study is to find the decision variables that minimize an overall cost, including repair, replacement, preventive maintenance, inventory holding and backlog costs over an infinite planning horizon. The proposed model is based on a semi-Markov decision process and the stochastic dynamic programming method is used to obtain the optimality conditions. A numerical example is given to illustrate the proposed model. A sensitivity analysis is considered to confirm the structure of the control policy and to illustrate the usefulness on the proposed approach.
Integrated production maintenance and quality model for imperfect processes
IIE Transactions, 1999
In this paper, we develop an integrated model for the joint optimization of the economic production quantity, the economic design of " x-control chart, and the optimal maintenance level. This is done for a deteriorating process where the in-control period follows a general probability distribution with increasing hazard rate. In the proposed model, Preventive Maintenance (PM) activities reduce the shift rate to the out-of-control state proportional to the PM level. Compared to the case with no PM, the extra cost of maintenance results in lower quality control cost which may lead to lower overall expected cost. These issues are illustrated using an example of a Weibull shock model with an increasing hazard rate. 0740-817X Ó 1999``IIE''
Integrated production planning and preventive maintenance in deteriorating production systems
Information Sciences an International Journal, 2008
This paper discusses the issue of integrating production planning and preventive maintenance in manufacturing production systems. In particular, it tackles the problem of integrating production and preventive maintenance in a system composed of parallel failure-prone production lines. It is assumed that when a production line fails, a minimal repair is carried out to restore it to an 'as-bad-as-old' status. Preventive maintenance is carried out, periodically at the discretion of the decision maker, to restore the production line to an 'as-good-as-new' status. It is also assumed that any maintenance action, performed on a production line in a given period, reduces the available production capacity on the line during that period. The resulting integrated production and maintenance planning problem is modeled as a nonlinear mixed-integer program when each production line implements a cyclic preventive maintenance policy. When noncyclical preventive maintenance policies are allowed, the problem is modeled as a linear mixed-integer program. A Lagrangian-based heuristic procedure for the solution of the first planning model is proposed and discussed. Computational experiments are carried out to analyze the performance of the method for different failure rate distributions, and the obtained results are discussed in detail.