Integrated analysis of quality and production logistics performance in manufacturing lines

Colledani, Marcello; Tolio, Tullio

doi:10.1080/00207540903443246

Cited by 90 publications

(35 citation statements)

References 38 publications

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“…A number of authors have proposed the link between deterioration and quality, such as Kim and Gershwin (2008) who suggested that in modeling the wear of the machine, it can also be used to represent different quality yields. Additionally, Colledani and Tolio (2011) claimed that the existence of a degrading process in production systems may have a continuous deterioration on the quality of parts. These references permit to define an inter-relationship between deterioration and quality.…”

Section: Deterioration Modelingmentioning

confidence: 99%

Joint control of production, overhaul, and preventive maintenance for a production system subject to quality and reliability deteriorations

Rivera-Gómez

Gharbi

Kenné

2013

Int J Adv Manuf Technol

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This research investigates the case of an unreliable manufacturing system subject to quality and reliability deterioration. In particular, we conjecture that the deterioration of the system leads to a continuous increase in the intensity of failures and a decrease on the quality of the parts produced. As such, deterioration implies a twofold effect on the manufacturing system. When the machine fails, minimal repair is conducted, leaving the machine at the same level of deterioration before failure. Hence, the quality of the parts produced and the failure intensity remain unchanged with this repair. Meanwhile, an overhaul refers to a perfect repair that completely restores the quality of the parts and the failure intensity of the machine. This option completely counters all the effects of the deterioration. Preventive maintenance may also be conducted, but it reduces the level of deterioration only partially, improving the quality of the units produced and the failure intensity just in part. These set of characteristics yield to the formulation of a new control model that simultaneously determines the optimal production plan, the overhaul and preventive maintenance strategies. Such a joint control policy minimizes the total cost including the inventory holding, backlog, overhaul, preventive maintenance and defectives costs over an infinite planning horizon. Since the dynamics of the system change as a function of the level of deterioration, it is necessary to use its history for a proper formulation; therefore a Semi-Markov decision process is used. Numerical methods are applied to determine the control policy and numerical examples are conducted as illustrations. An extensive sensitivity analysis is presented in order to confirm the structure of the control policy obtained and examine the effect of several parameters.

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Section: Deterioration Modelingmentioning

confidence: 99%

Joint control of production, overhaul, and preventive maintenance for a production system subject to quality and reliability deteriorations

Rivera-Gómez

Gharbi

Kenné

2013

Int J Adv Manuf Technol

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“…For example Kim and Gershwin (2008), proposed a general model that represents the wear of the machine and that also indicates different quality levels, implying a deterioration of quality. In the same direction Colledani and Tolio (2011) suggest that the degrading process of the machine has a continuous deterioration on the parts' quality. Even in the area of quality it exists a control charts for trends, where a gradual change in the part's feature is expected and considered to be normal given for instance by tool wears, as indicated in Besterfield (2009).…”

Section: Deteriorating Systemsmentioning

confidence: 96%

“…The decomposition method has been extensively applied to analyzed long production systems as in Bonvik et al (2000). In the same direction, the set of works of Colledani and Tolio (2006, 2009, 2011) presented a mathematical method based on discrete Markov chains to evaluate the performance of production systems with manufacturing and inspection machines, where the behavior of the machines were monitored with control charts. Nevertheless, the main difference between these works and our paper is that in the former, Markov chains and the decomposition technique are the main tools used in their analysis, whereas in this paper, we focus on the structure of the control policy derived from a semi-Markov model.…”

Section: Introductionmentioning

confidence: 99%

Production and quality control policies for deteriorating manufacturing system

Rivera-Gómez¹,

Gharbi²,

Kenné³

2013

International Journal of Production Research

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In this paper, a novel model for a deteriorating manufacturing system is analyzed, considering repairs and overhauls of random durations. The machine manufactures one product and the model is further complicated because the quality of the parts' produced deteriorates according to the wear of the machine and human interventions. When a breakdown occurs, either a repair or an overhaul is performed. The machine is restored to as-good-as-new conditions if the overhaul is selected, and conversely, its condition deteriorates following repairs. Multiple operational states are considered to define an aging process. The decision variables of the model are the production rate and the repair/overhaul switching strategy. This paper provides new insights to this research area by considering the simultaneous production and repair/overhaul control policy under the effect of deteriorations. The optimal decision policy minimizes the total incurred cost comprising the inventory, backlog, repair and overhaul costs over an infinite planning horizon. Our paper differs from other research projects in its consideration of the machine's history, defined by the number of repairs and multiple operational states. A numerical example is given to illustrate the proposed approach and a sensitivity analysis has been conducted to confirm the structure of the obtained control policies.

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“…Our primary concern in this model is that the quality of the parts produced is continuously deteriorated by the degrading process of the manufacturing system, as suggested by Colledani and Tolio (2011) and Kim and Gershwin (2008). These authors conceived the deterioration-quality relationship.…”

Section: Control Problem Statementmentioning

confidence: 99%

Joint production and major maintenance planning policy of a manufacturing system with deteriorating quality

Rivera-Gómez

Gharbi

Kenné

2013

International Journal of Production Economics

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We investigate the simultaneous production planning and quality control problem for an unreliable single machine manufacturing system responding to a single product type demand. The machine is subject to deteriorations, and their effect is observed mainly on the rate of defectives, which increases continuously over time. Due to the uncertainty caused by failures, the machine may not meet long-term demand, and an overhaul can be conducted in order to counter the effect of the deterioration. The main objective of this study is to simultaneously determine the optimal production plan and overhaul schedule for the analyzed manufacturing system, in order to minimize the total cost, comprising the inventory, backlog, repair and overhaul cost, over an infinite planning horizon. A stochastic dynamic programming model is proposed, in which a numerical scheme is adopted to solve the optimality condition equations. It is observed that the optimal control policy is described by a machine deterioration-dependent hedging point policy (MDDHPP). To accurately approximate the related control parameters, a simulation optimization approach based on design of experiments, simulation modeling and response surface methodology is applied. The results obtained provide a better understanding about the influence of the deterioration of quality in the production and overhaul policies. A numerical example and an extensive sensitivity analysis are conducted, and show the robust behavior and usefulness of the policy obtained.

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Integrated analysis of quality and production logistics performance in manufacturing lines

Cited by 90 publications

References 38 publications

Joint control of production, overhaul, and preventive maintenance for a production system subject to quality and reliability deteriorations

Joint control of production, overhaul, and preventive maintenance for a production system subject to quality and reliability deteriorations

Production and quality control policies for deteriorating manufacturing system

Joint production and major maintenance planning policy of a manufacturing system with deteriorating quality

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