Risk analysis for lot-sizing and maintenance optimization problem under energy constraint with subcontractor solution

Abstract

PurposeThe main contribution of this manuscript is to suggest new approaches in order to deal with dynamic lot-sizing and maintenance problem under aspect energetic and risk analysis. The authors introduce a new maintenance strategy based on the centroid approach to determine a common preventive maintenance plan for all machines to minimize the total maintenance cost. Thereafter, the authors suggest a risk analysis study further to unforeseen disruption of availability machines with the aim of helping the production stakeholders to achieve the obtained forecasting lot-size plan.Design/methodology/approachThe authors tackle the dynamic lot-sizing problem using an efficient hybrid approach based on random exploration and branch and bound method to generate possible solutions. Indeed, the feasible solutions of random exploration method are used as input for branch and bound to determine the near-optimal solution of lot-size plan. In addition, our contribution to the maintenance part is to determine the optimal common maintenance plan for M machines based on a new algorithm called preventive maintenance (PM) periods means.FindingsFirst, the authors have funded the optimal lot-size plan that should satisfy the random demand under service level requirement and energy constraint while minimizing the costs of production and inventory. Indeed, establishing a best lot-size plan is to determine the appropriate number of available machines and manufactured units per period. Second, for risk analysis study, the solution of subcontracting is proposed by specifying a maximum cost of subcontractor in the context of a calling of tenders.Originality/valueFor maintenance problem, the originality consists in regrouping the maintenance plans of M machines into only one plan. This approach lets us to minimize the total maintenance cost and reduces the frequent breaks of production. As a second part, this paper contributed to the development of a new risk analysis study further to unforeseen disruption of availability machines. This risk analysis developed a decision-making system, for production stakeholders, in order to achieve the forecasting lot-size plan and keeps its profitability, by specifying the unit cost threshold of subcontractor in the context of a calling of tender.

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

“…The proposed model defined appropriate countermeasures by considering the level of inventory, the evolution of defectives, and the dynamics of failures and repairs, and a continuous-time stochastic process was used to model the underlying dynamics of the production system. This research aimed to extend previous results of the conventional system presented in Assid et al [13] and mainly in the studies of Rivera-Gómez et al [17][18][19][20][21][22][23][24][25][26][27][28], which investigated the effective coordination of production and subcontracting policies in the case of progressive quality decline. The mathematical complexity and the stochastic behavior of the proposed production system imposed several challenges, which were overcome with the use of a methodology based on several techniques, such as a semi-Markov process, stochastic optimal control, and simulationbased optimization.…”

“…Rivera-Gómez et al [17] investigated the problem of a deteriorating system with effects on quality and reliability with the aim to determine production and subcontracting strategies; in this study, preventive maintenance could be conducted to mitigate the effects of the deterioration process. In Kammoun et al [18], subcontracting was allowed in a dynamic lot-sizing problem for a system that satisfied random demand and had requirements in the service level and consumption of energy. In their maintenance strategy, they regrouped the maintenance plans of several machines into only one plan.…”

“…In this table, the rows classify the studies presented in the literature review in five main areas, and the columns present the key factors investigated in these studies. [4] Rivera-Gómez et al [5] Hajej and Rezg [6] (b) Production-quality-maintenance strategies Bouslah et al [7] Fakher et al [8] Cheng et al [9] Abubakar et al [10] Ait-El-Cadi et al [11] Hajej et al [12] (c) Production and subcontracting planning Assid et al [13] Ben-Salem et al [14] Haoues et al [15] Ayed et al [16] Rivera-Gómez et al [17] Kammoun et al [18] (d) Deteriorating systems Boudhar et al [19] Martinod et al [20] Ouaret et al [21] Polotski et al [22] Dellagi et al [23] Magnanini and Tolio [24] (e) Simulation approach Hosseini and Tan [25] Guiras et al [26] Abdolmaleki et al [27] Rivera-Gómez et al [28] Assid et al [29] Ait-El-Cadi et al [30] (f) Additional issues Fathollahi-Fard et al [31] Jian et al [32] Villalonga et al [33] Chen et al [34] Fathollahi-Fard et al [35] Gholizadeh et al [36] Villalonga et al [37] The proposed model…”

Imperfect Preventive Maintenance Planning Optimization for Leased Machines

“…Gouiaa et al ( 2018) discussed the integrated model of economic production, obtained quantity and maintenance policy. Recently, Kammoun et al (2020) proposed new approach to deal with dynamic lot-sizing and maintenance problem under aspect energetic. They introduced a novel maintenance strategy to determine a common preventive maintenance plan for several machines to minimize the total maintenance cost.…”