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Integrated production, quality control and condition-based maintenance for imperfect production systems

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  • Cheng, Guo Qing
  • Zhou, Bing Hai
  • Li, Ling

Abstract

This paper considers an integrated problem of production lot sizing, quality control and condition-based maintenance for an imperfect production system subject to both reliability and quality degradations. The system produces a single type of product to meet constant demand. To provide protection to the stock against uncertainties, a make-to-stock production policy is employed. The condition-based maintenance policy consists in carrying out inspections at the end of production runs to evaluate system condition and performing imperfect preventive maintenance if detected degradation level exceeds the threshold. The quality control is performed by using 100% inspection policy to obtain the proportion of defectives. Based on the quality information feedback, an overhaul action is conducted once the proportion reaches a given threshold during production runs. The aim of this paper is to jointly optimize the lot size, the inventory threshold, the preventive maintenance and overhaul thresholds such that the total cost per unit time is minimized. A stochastic mathematical model is formulated and solved by a simulation-based optimization approach coupling Monte Carlo Simulation and Response Surface Methodology. Finally, an illustrative example and sensitivity analyses are provided to demonstrate the proposed model.

Suggested Citation

  • Cheng, Guo Qing & Zhou, Bing Hai & Li, Ling, 2018. "Integrated production, quality control and condition-based maintenance for imperfect production systems," Reliability Engineering and System Safety, Elsevier, vol. 175(C), pages 251-264.
    • Handle: RePEc:eee:reensy:v:175:y:2018:i:c:p:251-264
    DOI: 10.1016/j.ress.2018.03.025
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    3. K.Y. Kung & Y.D. Huang & H.M. Wee & Y. Daryanto, 2019. "Production-Inventory System for Deteriorating Items with Machine Breakdown, Inspection, and Partial Backordering," Mathematics, MDPI, vol. 7(7), pages 1-26, July.
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    5. Zhang, Nan & Cai, Kaiquan & Deng, Yingjun & Zhang, Jun, 2024. "Joint optimization of condition-based maintenance and condition-based production of a single equipment considering random yield and maintenance delay," Reliability Engineering and System Safety, Elsevier, vol. 241(C).
    6. Lin Wang & Zhiqiang Lu & Yifei Ren, 2019. "A rolling horizon approach for production planning and condition-based maintenance under uncertain demand," Journal of Risk and Reliability, , vol. 233(6), pages 1014-1028, December.
    7. Zhou, Yifan & Guo, Yiming & Lin, Tian Ran & Ma, Lin, 2018. "Maintenance optimisation of a series production system with intermediate buffers using a multi-agent FMDP," Reliability Engineering and System Safety, Elsevier, vol. 180(C), pages 39-48.
    8. Li, Yao & He, Yihai & Liao, Ruoyu & Zheng, Xin & Dai, Wei, 2022. "Integrated predictive maintenance approach for multistate manufacturing system considering geometric and non-geometric defects of products," Reliability Engineering and System Safety, Elsevier, vol. 228(C).
    9. Adjoul, Oussama & Benfriha, Khaled & Zant, Chawki El & Aoussat, Améziane, 2021. "Algorithmic Strategy for Simultaneous Optimization of Design and Maintenance of Multi-Component Industrial Systems," Reliability Engineering and System Safety, Elsevier, vol. 208(C).
    10. Wang, Lin & Lu, Zhiqiang & Ren, Yifei, 2020. "Joint production control and maintenance policy for a serial system with quality deterioration and stochastic demand," Reliability Engineering and System Safety, Elsevier, vol. 199(C).
    11. Boumallessa, Zeineb & Chouikhi, Houssam & Elleuch, Mounir & Bentaher, Hatem, 2023. "Modeling and optimizing the maintenance schedule using dynamic quality and machine condition monitors in an unreliable single production system," Reliability Engineering and System Safety, Elsevier, vol. 235(C).
    12. Rajesh Saha & Abdullahil Azeem & Kazi Wahadul Hasan & Syed Mithun Ali & Sanjoy Kumar Paul, 2021. "Integrated economic design of quality control and maintenance management: Implications for managing manufacturing process," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 12(2), pages 263-280, April.
    13. Xu, Jun & Liang, Zhenglin & Li, Yan-Fu & Wang, Kaibo, 2021. "Generalized condition-based maintenance optimization for multi-component systems considering stochastic dependency and imperfect maintenance," Reliability Engineering and System Safety, Elsevier, vol. 211(C).
    14. Ye, Zhenggeng & Cai, Zhiqiang & Yang, Hui & Si, Shubin & Zhou, Fuli, 2023. "Joint optimization of maintenance and quality inspection for manufacturing networks based on deep reinforcement learning," Reliability Engineering and System Safety, Elsevier, vol. 236(C).
    15. Gao, Kaiye & Peng, Rui & Qu, Li & Wu, Shaomin, 2020. "Jointly optimizing lot sizing and maintenance policy for a production system with two failure modes," Reliability Engineering and System Safety, Elsevier, vol. 202(C).
    16. uit het Broek, Michiel A.J. & Teunter, Ruud H. & de Jonge, Bram & Veldman, Jasper, 2021. "Joint condition-based maintenance and condition-based production optimization," Reliability Engineering and System Safety, Elsevier, vol. 214(C).
    17. Ye, Zhenggeng & Yang, Hui & Cai, Zhiqiang & Si, Shubin & Zhou, Fuli, 2021. "Performance evaluation of serial-parallel manufacturing systems based on the impact of heterogeneous feedstocks on machine degradation," Reliability Engineering and System Safety, Elsevier, vol. 207(C).
    18. Ait-El-Cadi, Abdessamad & Gharbi, Ali & Dhouib, Karem & Artiba, Abdelhakim, 2021. "Integrated production, maintenance and quality control policy for unreliable manufacturing systems under dynamic inspection," International Journal of Production Economics, Elsevier, vol. 236(C).
    19. de Jonge, Bram & Scarf, Philip A., 2020. "A review on maintenance optimization," European Journal of Operational Research, Elsevier, vol. 285(3), pages 805-824.
    20. Yifan Zhou & Chao Yuan & Tian Ran Lin & Lin Ma, 2021. "Maintenance policy structure investigation and optimisation of a complex production system with intermediate buffers," Journal of Risk and Reliability, , vol. 235(3), pages 458-473, June.
    21. Shuyuan Gan & Bolun Wang & Zhifang Song, 2021. "A Combined Maintenance Strategy Considering Spares, Buffer, and Quality," Journal of Risk and Reliability, , vol. 235(3), pages 431-445, June.
    22. Azimpoor, Samareh & Taghipour, Sharareh, 2021. "Joint inspection and product quality optimization for a system with delayed failure," Reliability Engineering and System Safety, Elsevier, vol. 215(C).
    23. Rasay, Hasan & Taghipour, Sharareh & Sharifi, Mani, 2022. "An integrated Maintenance and Statistical Process Control Model for a Deteriorating Production Process," Reliability Engineering and System Safety, Elsevier, vol. 228(C).
    24. Cheng, Guoqing & Li, Ling, 2020. "Joint optimization of production, quality control and maintenance for serial-parallel multistage production systems," Reliability Engineering and System Safety, Elsevier, vol. 204(C).

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