Production, preventive and corrective maintenance planning in manufacturing systems under imperfect repairs

Abstract

This paper deals with the joint analysis of the optimal production and maintenance planning problems for a manufacturing system subject to random failures and repairs. When a machine fails down, an imperfect repair is undertaken. The objective of this study is to minimize a discounted overall cost consisting of preventive and corrective maintenance costs, inventory holding cost and backlog cost. A two-level hierarchical decision making approach, based on the determination of the mean time between failures (first level) and the statement of a joint optimization of production, preventive and corrective maintenance policies (second level) is proposed. Hence the production, preventive and corrective maintenance rates are determined in level 2 given the failure rates obtained from level 1. In the proposed model, the failure rate of the machine depends on the number of failures; hence, the control policies of the considered planning problem depend on the number of failures. A numerical example and a sensitivity analysis will illustrate the structure of the optimal control policies and the usefulness on the proposed approach. Keywords: Imperfect repairs; Manufacturing Systems; Preventive and Corrective Maintenance. IntroductionThe reliability of a manufacturing system depends on the quality of its conception and the actions of the maintenance which are undertaken during its exploitation (production activities). This paper deals with the control problem of a stochastic manufacturing system consisting of one machine producing one part type. The stochastic nature of the system is due to the fact that the machine is subject to random breakdowns and repairs. Upon a failure of a component of the machine, an imperfect repair is undertaken. The machine dynamics is assumed herein to be described by a finite state semi-Markov chain. The decision variables are the production, the preventive and the corrective maintenance rates, which influence the availability of the system and the stock level. Many authors have contributed to the production planning problem of manufacturing systems (Boukas (1998)), without considering the failure rates depending on the number of failures and the production control in the same model. The aim of this paper is to propose a production control and maintenance (preventive and corrective) planning for a manufacturing system subject to imperfect repairs, when the failure rate increases with the number of failures. The proposed hierarchical approach consists in developing a model where at the first level; the parameters of the machine failure stochastic process are derived for each number of failures. At the second level, we determine the optimal production, preventive and corrective maintenance policies for a system that deteriorates with the number of failures. We obtain a

Impact of Unreliable Subcontracting on Production and Maintenance Planning Considering Quality Decline

“…We note that the key parameters presented in the columns of Table 1 follow the evolution of the field of manufacturing systems. For instance, from the presented studies, it is clear that the first research trend focused on the development of production-maintenance strategies, as observed in the studies of Kouedeu et al [1], Dellagi et al [2], Fitouhi et al [3], etc. Then, since 2013, the quality trend appeared, and thus, several studies included quality issues in their formulation, as in Bouslah et al [7], Fakher et al [8], Cheng et al [9], etc.…”

“…When analyzing the literature on the integration of production and maintenance strategies, we observed that several works were conducted, which makes sense given that current production systems have become more complex. For instance, Kouedeu et al [1] studied a hierarchical decision-making process, where, in the first level, they determined the mean time to failure, and in the second level, they determined the production and maintenance rates. They assumed imperfect maintenance actions.…”

“…A2. The demand was known and constant during the considered production horizon, as in Kouedeu et al [1].…”

Electrical Network Maintenance: A Review

“…Множество работ, касающихся организации ТОиР, направлены на определение оптимального соотношения корректирующего и превентивного ТО [5][6][7][8], то есть специалисты в области обеспечения эксплуатационной надежности не категоричны в своем стремлении изжить любыми средствами случайные отказы. Решающим фактором выбора типа ТО (в том числе и корректирующего) для конкретного оборудования является рациональная организация эксплуатации с технической и экономической точки зрения, и в этом аспекте корректирующее обслуживание является составляющей ТОиР, ориентированного на надежность (рассмотрено ниже).…”

Model Based Approach To Identify Optimal System Structures and Maintenance Policies for Safety Interlocks with Time-Varying Failure Rates

“…By maximizing the asymptotic availability and minimizing the cost rate, one can determine the number of inspections before replacement and the initial inspection interval. Kouedeu et al proposed a two-level hierarchical decision-making approach to compute the mean time to failure in the first level and to simultaneously optimize the production rate and the maintenance policies in the second level. Finally, Wang and Pham thoroughly reviewed the state of the art in reliability and maintenance modeling, including repair maintenance, replacement policy, inspection policy and maintenance modeling for complex systems.…”