Production control in a failure-prone manufacturing network using discrete event simulation and automated response surface methodology

Sajadi, Seyed Mojtaba; Esfahani, Mir Mehdi Seyed; Sörensen, Kenneth

doi:10.1007/s00170-010-2814-0

Cited by 45 publications

(22 citation statements)

References 15 publications

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“…For the manufacturing system considered, the joint control policy is given by Equations (25)- (27) and Figures 5 to 7. It is also important to note that the deterioration phenomenon influences the dynamics of several variables of the system, since on denoting deterioration with the age of the machine, its variation implies changes in the rate of defectives and the MTTF.…”

Section: Discussionmentioning

confidence: 99%

“…Bearing in mind the numerical results obtained so far, we can state that the simultaneous production, overhaul and preventive maintenance policy are perfectly defined by Equations (25)- (27) and implementing this control policy is possible to govern the manufacturing system by monitoring the stock level and the deterioration of the machine, denoted by its age a . The production policy can be completely parameterized by the control factor * • , meanwhile the overhaul and preventive maintenance policies can be defined by the zones and , respectively.…”

Section: Preventive Maintenance Policymentioning

confidence: 99%

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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: Discussionmentioning

confidence: 99%

Section: Preventive Maintenance Policymentioning

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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“…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].…”

Section: Product Quality Improvementmentioning

confidence: 99%

Use of IT technologies in the management of production process quality

Milewska

Skowron²

2018

MATEC Web Conf.

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Abstract. When presenting the functionality of IPOsystem™, the author of the article described the manner of controlling the quality of products and calculating the technical cost of production in a selected production plant. In the article actions taken to remove product quality nonconformities have been discussed and a calculation by the subtractive factor method has been presented. Limitations of the described IT tools have also been illustrated with an example of implementation.

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“…This approach combines simulation modelling, experimental design and Response Surface Methodology. This approach was applied in different field such as production control problem [30] and an integrated production, overhaul and preventive maintenance problem [31]. The structure of the proposed control approach is as follows:…”

Section: Resolution Approachmentioning

confidence: 99%

Integrated quality strategy in production and raw material replenishment in a manufacturing-oriented supply chain

Hlioui

Gharbi

Hajji

2015

Int J Adv Manuf Technol

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Abstract:This paper deals with the coordination of production, replenishment and inspection decisions for a manufacturing-oriented supply chain with a failure-prone transformation stage, random lead-time and imperfect delivered lots. Upon reception of the lot, the manufacturer executes an acceptance sampling plan with a zero nonconforming criterion. If the sample does not contain non-conforming items, the lot is accepted; otherwise, it is rejected. In this work, two strategies regarding the refused sampled lot are studied. The first one involves a return of the lot to the supplier, who commits to improving the quality of the lot, while the second assumes that the manufacturer performs a 100% inspection and rectification operation. This work presents two main objectives. The first one is to jointly optimize, in a stochastic and dynamic context, the ordering point of raw material, the lot size of raw material, the final product inventory threshold and the severity of the sampling plan using a simulation-based optimization approach. The second one is to determine the best of the two quality control strategy. The in-depth study has shown that no strategy could be preferred in all the cases. For this reasons, we present an easy decision-making tool (Indifference curves) to help the manager to select the best quality control strategy when considering the entire supply chain.

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Production control in a failure-prone manufacturing network using discrete event simulation and automated response surface methodology

Cited by 45 publications

References 15 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

Use of IT technologies in the management of production process quality

Integrated quality strategy in production and raw material replenishment in a manufacturing-oriented supply chain

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