Joint optimal production control/preventive maintenance policy for imperfect process manufacturing cell

Abstract

Production, maintenance, and quality are often modeled as separate problems, despite the strong link that exists between these primary components of any manufacturing system. This paper deals with an integrated approach for the joint optimization of production-inventory control and preventive maintenance policy for a manufacturing cell comprising an imperfect process where the 'in-control' period have a general deterioration distribution. The production-inventory control policy based on the hedging point policy consists of building and maintaining a security stock of finished products in order to respond to demand and to avoid shortages during restoration actions. Restoration actions are planned when the system switches to the 'out-of-control' state and starts producing non-conforming items. The manufacturing cell is also subject to an age-based preventive maintenance policy in order to reduce the shift rate to the 'out-of-control' state. The main objective of this paper is to determine the joint optimal policy that minimizes the overall cost, which is comprised of setup, maintenance, inventory holding and shortage costs, as well as the cost incurred by producing non-conforming items. A mathematical model is proposed, and the expression of the overall incurred cost is derived and used as a basis for the optimal determination of the joint production-inventory control and preventive maintenance policy. These issues are illustrated using numerical examples. It is found that performing preventive maintenance will yield reductions in the overall incurred cost. Sensitivity analyses are also carried out in order to illustrate the robustness of the proposed methodology.

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

“…Also they define the size of the buffer stock. On their part, Dhouib et al (2012) proposed a model that determines the production control and the age-based preventive maintenance policy that reduces the shift rate to the out of control state, where the system produces defective products. Recently, Rivera-Gómez et al (2013) treated a deteriorating system where the quality of the parts decreases by the influence of the natural wear of the machine and imperfect repairs.…”

Modelling Production Performance of Small Scale Production Plant

“…Likewise, if CU increases, then the industry is operating with a positive output gap which contributes to reduce the unit cost of a product [18]. This statement is supported by past literatures that increasing capacity utilization contributes to reduce overall cost such as setup, maintenance, inventory holding, shortage cost and cost incurred by low quality products [19]. Factors affecting CU in production process are such as machineries transforming capability, skill of machine operators, working environment, degree of maintenance in machineries and raw material quality [20].…”

“…CU is an important tool for production and operations management to evaluate production performance and formulate strategy to reduce non-value input that appears as productivity gap [5], [17], [21]. Past literatures demonstrated increase in CU contributes to reduce overall cost such as setup, maintenance, inventory holding, shortage cost and quality cost [19], [22]. Better CU, efficient capacity planning and management are the key to improve production performance [23]- [26].…”

Use of IT technologies in the management of production process quality

“…Manufacturing process control is an important aspect of enterprise activity [3][4][5][6][7][8][9]. Based on numerous studies regarding production costs analysis, one can conclude that failure to meet quality requirements is frequently a source of additional costs, causing unexpected financial losses for the enterprise [10,11].…”