IDEAS home Printed from https://ideas.repec.org/a/spr/flsman/v34y2022i2d10.1007_s10696-021-09410-1.html
   My bibliography  Save this article

Integrated optimization on production scheduling and imperfect preventive maintenance considering multi-degradation and learning-forgetting effects

Author

Listed:
  • Xiufang Zhang

    (Shanghai Jiao Tong University)

  • Tangbin Xia

    (Shanghai Jiao Tong University)

  • Ershun Pan

    (Shanghai Jiao Tong University)

  • Yuqing Li

    (Shanghai Jiao Tong University)

Abstract

This paper proposes a multi-objective integrated optimization model of production scheduling and machine maintenance to find the optimal production sequence and preventive maintenance (PM) decisions. This model considers the setup time, the learning-forgetting effects and the multi-degradation effects. The setup time and the learning-forgetting effects are associated with jobs' similarities and PM decisions. The multi-degradation effects including machine deterioration, failure rate and quality characteristic loss determine the stochastic nature of the objectives. A hybrid maintenance strategy combining imperfect PM and minimal repair (MR) is adopted to effectively reduce the failure frequency and improve the processing quality. Then, the multi-objective solution is simplified by normalizing cost, time and utilization. The local search and the elitism strategy are conducted to avoid the solutions falling into local optimum and losing the best chromosome during evolutions. Finally, a case study of automobile engine manufacturing shows that our proposed model can reduce the total maintenance costs by 27%, shorten the total processing time by 3%, as well as improve the machine utilization by 3%.

Suggested Citation

  • Xiufang Zhang & Tangbin Xia & Ershun Pan & Yuqing Li, 2022. "Integrated optimization on production scheduling and imperfect preventive maintenance considering multi-degradation and learning-forgetting effects," Flexible Services and Manufacturing Journal, Springer, vol. 34(2), pages 451-482, June.
    • Handle: RePEc:spr:flsman:v:34:y:2022:i:2:d:10.1007_s10696-021-09410-1
    DOI: 10.1007/s10696-021-09410-1
    as

    Download full text from publisher

    File URL: http://link.springer.com/10.1007/s10696-021-09410-1
    File Function: Abstract
    Download Restriction: Access to the full text of the articles in this series is restricted.
    File URL: https://libkey.io/10.1007/s10696-021-09410-1?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to search for a different version of it.

    References listed on IDEAS

    as
    1. Jiawen Hu & Zuhua Jiang & Haitao Liao, 2017. "Preventive maintenance of a batch production system under time-varying operational condition," International Journal of Production Research, Taylor & Francis Journals, vol. 55(19), pages 5681-5705, October.
    2. Fitouhi, Mohamed-Chahir & Nourelfath, Mustapha, 2014. "Integrating noncyclical preventive maintenance scheduling and production planning for multi-state systems," Reliability Engineering and System Safety, Elsevier, vol. 121(C), pages 175-186.
    3. Héctor Rivera-Gómez & Jorge Lara & Oscar Montaño-Arango & Eva Selene Hernández-Gress & José Ramón Corona-Armenta & Francisca Santana-Robles, 2019. "Joint production and repair efficiency planning of a multiple deteriorating system," Flexible Services and Manufacturing Journal, Springer, vol. 31(2), pages 446-471, June.
    4. Liu, Xuejuan & Wang, Wenbin & Peng, Rui, 2015. "An integrated production, inventory and preventive maintenance model for a multi-product production system," Reliability Engineering and System Safety, Elsevier, vol. 137(C), pages 76-86.
    5. Mosheiov, Gur, 2001. "Scheduling problems with a learning effect," European Journal of Operational Research, Elsevier, vol. 132(3), pages 687-693, August.
    6. Daniel Tonke & Martin Grunow, 2018. "Maintenance, shutdown and production scheduling in semiconductor robotic cells," International Journal of Production Research, Taylor & Francis Journals, vol. 56(9), pages 3306-3325, May.
    7. M. A. Pasha & M. Bameni Moghadam & Y. Khadem & S. Fani, 2017. "An integration of Taguchi’s loss function in Banerjee–Rahim model for the economic and economic statistical design of X‾$\bar{X}$-control charts under multiple assignable causes and Weibull shock mode," Communications in Statistics - Theory and Methods, Taylor & Francis Journals, vol. 46(24), pages 12113-12129, December.
    8. M. A. Pasha & M. B. Moghadam & S. Fani & Y. Khadem, 2018. "Effects of quality characteristic distributions on the integrated model of Taguchi's loss function and economic statistical design of X‾$\bar{X}$-control charts by modifying the Banerjee and Rahim eco," Communications in Statistics - Theory and Methods, Taylor & Francis Journals, vol. 47(8), pages 1842-1855, April.
    9. Assid, M. & Gharbi, A. & Dhouib, K., 2015. "Joint production and subcontracting planning of unreliable multi-facility multi-product production systems," Omega, Elsevier, vol. 50(C), pages 54-69.
    10. Xia, Tangbin & Jin, Xiaoning & Xi, Lifeng & Ni, Jun, 2015. "Production-driven opportunistic maintenance for batch production based on MAM–APB scheduling," European Journal of Operational Research, Elsevier, vol. 240(3), pages 781-790.
    11. Liao, Haitao & Elsayed, Elsayed A. & Chan, Ling-Yau, 2006. "Maintenance of continuously monitored degrading systems," European Journal of Operational Research, Elsevier, vol. 175(2), pages 821-835, December.
    12. Xiao, Lei & Song, Sanling & Chen, Xiaohui & Coit, David W., 2016. "Joint optimization of production scheduling and machine group preventive maintenance," Reliability Engineering and System Safety, Elsevier, vol. 146(C), pages 68-78.
    13. Feng, Hanxin & Xi, Lifeng & Xiao, Lei & Xia, Tangbin & Pan, Ershun, 2018. "Imperfect preventive maintenance optimization for flexible flowshop manufacturing cells considering sequence-dependent group scheduling," Reliability Engineering and System Safety, Elsevier, vol. 176(C), pages 218-229.
    14. Biskup, Dirk, 1999. "Single-machine scheduling with learning considerations," European Journal of Operational Research, Elsevier, vol. 115(1), pages 173-178, May.
    15. Rivera-Gómez, Héctor & Gharbi, Ali & Kenné, Jean-Pierre & Montaño-Arango, Oscar & Hernandez-Gress, Eva Selene, 2016. "Production control problem integrating overhaul and subcontracting strategies for a quality deteriorating manufacturing system," International Journal of Production Economics, Elsevier, vol. 171(P1), pages 134-150.
    16. Fahimeh Shamsaei & Mathieu Vyve, 2017. "Solving integrated production and condition-based maintenance planning problems by MIP modeling," Flexible Services and Manufacturing Journal, Springer, vol. 29(2), pages 184-202, June.
    17. Aghezzaf, El-Houssaine & Khatab, Abdelhakim & Tam, Phuoc Le, 2016. "Optimizing production and imperfect preventive maintenance planning׳s integration in failure-prone manufacturing systems," Reliability Engineering and System Safety, Elsevier, vol. 145(C), pages 190-198.
    18. Mosheiov, Gur & Sidney, Jeffrey B., 2003. "Scheduling with general job-dependent learning curves," European Journal of Operational Research, Elsevier, vol. 147(3), pages 665-670, June.
    19. Alex J. Ruiz-Torres & Giuseppe Paletta & Rym M’Hallah, 2017. "Makespan minimisation with sequence-dependent machine deterioration and maintenance events," International Journal of Production Research, Taylor & Francis Journals, vol. 55(2), pages 462-479, January.
    20. Shang-Chia Liu & Wei-Ling Hung & Chin-Chia Wu, 2015. "Note on a Single-Machine Scheduling Problem with Sum of Processing Times Based Learning and Ready Times," Mathematical Problems in Engineering, Hindawi, vol. 2015, pages 1-9, July.
    21. Biskup, Dirk, 2008. "A state-of-the-art review on scheduling with learning effects," European Journal of Operational Research, Elsevier, vol. 188(2), pages 315-329, July.
    22. Kenné, Jean-Pierre & Gharbi, Ali, 2018. "Production and replacement policies for a deteriorating manufacturing system under random demand and qualityAuthor-Name: Ouaret, Samir," European Journal of Operational Research, Elsevier, vol. 264(2), pages 623-636.
    23. Wen-Hung Kuo, 2012. "Single-machine group scheduling with time-dependent learning effect and position-based setup time learning effect," Annals of Operations Research, Springer, vol. 196(1), pages 349-359, July.
    24. Fahimeh SHAMSAEI & Mathieu VAN VYVE, 2017. "Solving integrated production and condition-based maintenance planning problems by MIP modeling," LIDAM Reprints CORE 2896, Université catholique de Louvain, Center for Operations Research and Econometrics (CORE).
    25. A. Khatab, 2018. "Maintenance optimization in failure-prone systems under imperfect preventive maintenance," Journal of Intelligent Manufacturing, Springer, vol. 29(3), pages 707-717, March.
    26. Bouslah, B. & Gharbi, A. & Pellerin, R., 2016. "Integrated production, sampling quality control and maintenance of deteriorating production systems with AOQL constraint," Omega, Elsevier, vol. 61(C), pages 110-126.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Ualison Rébula De Oliveira & Hilda Anatiely Donato Souza & Carlos Augusto Gabriel Menezes & Henrique Martins Rocha, 2023. "Straightening machine preventive maintenance intervention plan based on AHP: a case study in a steel company in Brazil," Operations Management Research, Springer, vol. 16(3), pages 1577-1593, September.

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Liu, Yu & Zhang, Qin & Ouyang, Zhiyuan & Huang, Hong-Zhong, 2021. "Integrated production planning and preventive maintenance scheduling for synchronized parallel machines," Reliability Engineering and System Safety, Elsevier, vol. 215(C).
    2. Xingong Zhang & Guangle Yan & Wanzhen Huang & Guochun Tang, 2011. "Single-machine scheduling problems with time and position dependent processing times," Annals of Operations Research, Springer, vol. 186(1), pages 345-356, June.
    3. Finke, Gerd & Gara-Ali, Ahmed & Espinouse, Marie-Laure & Jost, Vincent & Moncel, Julien, 2017. "Unified matrix approach to solve production-maintenance problems on a single machine," Omega, Elsevier, vol. 66(PA), pages 140-146.
    4. Gössinger, Ralf & Helmke, Hanna & Kaluzny, Michael, 2017. "Condition-based release of maintenance jobs in a decentralised production-maintenance system – An analysis of alternative stochastic approaches," International Journal of Production Economics, Elsevier, vol. 193(C), pages 528-537.
    5. Ji-Bo Wang & Ming-Zheng Wang, 2011. "Worst-case behavior of simple sequencing rules in flow shop scheduling with general position-dependent learning effects," Annals of Operations Research, Springer, vol. 191(1), pages 155-169, November.
    6. Shang-Chia Liu, 2015. "Common Due-Window Assignment and Group Scheduling with Position-Dependent Processing Times," Asia-Pacific Journal of Operational Research (APJOR), World Scientific Publishing Co. Pte. Ltd., vol. 32(06), pages 1-19, December.
    7. Qian, Jin & Lin, Hexiang & Kong, Yufeng & Wang, Yuansong, 2020. "Tri-criteria single machine scheduling model with release times and learning factor," Applied Mathematics and Computation, Elsevier, vol. 387(C).
    8. Feng, Hanxin & Xi, Lifeng & Xiao, Lei & Xia, Tangbin & Pan, Ershun, 2018. "Imperfect preventive maintenance optimization for flexible flowshop manufacturing cells considering sequence-dependent group scheduling," Reliability Engineering and System Safety, Elsevier, vol. 176(C), pages 218-229.
    9. Dar-Li Yang & Wen-Hung Kuo, 2009. "Single-machine scheduling with both deterioration and learning effects," Annals of Operations Research, Springer, vol. 172(1), pages 315-327, November.
    10. Rustogi, Kabir & Strusevich, Vitaly A., 2012. "Simple matching vs linear assignment in scheduling models with positional effects: A critical review," European Journal of Operational Research, Elsevier, vol. 222(3), pages 393-407.
    11. Xia, Tangbin & Dong, Yifan & Xiao, Lei & Du, Shichang & Pan, Ershun & Xi, Lifeng, 2018. "Recent advances in prognostics and health management for advanced manufacturing paradigms," Reliability Engineering and System Safety, Elsevier, vol. 178(C), pages 255-268.
    12. W-H Kuo & D-L Yang, 2011. "A note on due-date assignment and single-machine scheduling with deteriorating jobs and learning effects," Journal of the Operational Research Society, Palgrave Macmillan;The OR Society, vol. 62(1), pages 206-210, January.
    13. Rustogi, Kabir & Strusevich, Vitaly A., 2012. "Single machine scheduling with general positional deterioration and rate-modifying maintenance," Omega, Elsevier, vol. 40(6), pages 791-804.
    14. Heuser, Patricia & Tauer, Björn, 2023. "Single-machine scheduling with product category-based learning and forgetting effects," Omega, Elsevier, vol. 115(C).
    15. Biskup, Dirk, 2008. "A state-of-the-art review on scheduling with learning effects," European Journal of Operational Research, Elsevier, vol. 188(2), pages 315-329, July.
    16. Xiao, Lei & Zhang, Xinghui & Tang, Junxuan & Zhou, Yaqin, 2020. "Joint optimization of opportunistic maintenance and production scheduling considering batch production mode and varying operational conditions," Reliability Engineering and System Safety, Elsevier, vol. 202(C).
    17. Jiang, Junwei & An, Youjun & Dong, Yuanfa & Hu, Jiawen & Li, Yinghe & Zhao, Ziye, 2023. "Integrated optimization of non-permutation flow shop scheduling and maintenance planning with variable processing speed," Reliability Engineering and System Safety, Elsevier, vol. 234(C).
    18. Kai-biao Sun & Hong-xing Li, 2009. "Some single-machine scheduling problems with actual time and position dependent learning effects," Fuzzy Information and Engineering, Springer, vol. 1(2), pages 161-177, June.
    19. Jiang, Zhongyi & Chen, Fangfang & Kang, Huiyan, 2013. "Single-machine scheduling problems with actual time-dependent and job-dependent learning effect," European Journal of Operational Research, Elsevier, vol. 227(1), pages 76-80.
    20. Qian, Jianbo & Steiner, George, 2013. "Fast algorithms for scheduling with learning effects and time-dependent processing times on a single machine," European Journal of Operational Research, Elsevier, vol. 225(3), pages 547-551.

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:spr:flsman:v:34:y:2022:i:2:d:10.1007_s10696-021-09410-1. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Sonal Shukla or Springer Nature Abstracting and Indexing (email available below). General contact details of provider: http://www.springer.com .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.