IDEAS home Printed from https://ideas.repec.org/a/eee/jomega/v61y2016icp110-126.html
   My bibliography  Save this article

Integrated production, sampling quality control and maintenance of deteriorating production systems with AOQL constraint

Author

Listed:
  • Bouslah, B.
  • Gharbi, A.
  • Pellerin, R.

Abstract

This paper considers the problem of integrated production, preventive maintenance and quality control for a stochastic production system subject to both reliability and quality deteriorations. A make-to-stock production strategy is used to provide protection to the serviceable stock against uncertainties. The quality control is performed using a single acceptance sampling plan by attributes. The preventive maintenance strategy consists in carrying out an imperfect maintenance as a part of the setup activity at the beginning of each lot production, while a major maintenance (overhaul) is undertaken once the proportion of defectives in a rejected lot reaches or exceeds a given threshold. The main objective of this study is to jointly optimize the production lot size, the inventory threshold, the sampling plan parameters and the overhaul threshold by minimizing the total incurred cost. To meet customer requirements, the optimization problem is subject to a specified constraint on the average outgoing quality limit (AOQL). A stochastic mathematical model is developed and solved using a simulation-based optimization approach. Numerical examples and thorough sensitivity analyses are provided to illustrate the efficiency of the proposed integrated model. Compared with the 100% inspection policy which is widely used in the literature on integrated production, maintenance and quality control, the results obtained show that an economic design of acceptance sampling in such an integrated context can lead to important cost savings of more than 20%.

Suggested Citation

  • 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.
  • Handle: RePEc:eee:jomega:v:61:y:2016:i:c:p:110-126
    DOI: 10.1016/j.omega.2015.07.012
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0305048315001541
    Download Restriction: Full text for ScienceDirect subscribers only

    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. Camino GonzALez & Gabriel Palomo, 2003. "Bayesian acceptance sampling plans following economic criteria: An application to paper pulp manufacturing," Journal of Applied Statistics, Taylor & Francis Journals, vol. 30(3), pages 319-333.
    2. Goyal, S. K. & Gunasekaran, A. & Martikainen, T. & Yli-Olli, P., 1993. "Integrating production and quality control policies: A survey," European Journal of Operational Research, Elsevier, vol. 69(1), pages 1-13, August.
    3. Jeang, Angus, 2012. "Simultaneous determination of production lot size and process parameters under process deterioration and process breakdown," Omega, Elsevier, vol. 40(6), pages 774-781.
    4. Wee, Hui Ming & Widyadana, Gede Agus, 2013. "A production model for deteriorating items with stochastic preventive maintenance time and rework process with FIFO rule," Omega, Elsevier, vol. 41(6), pages 941-954.
    5. Hajji, A. & Mhada, F. & Gharbi, A. & Pellerin, R. & Malhamé, R., 2011. "Integrated product specifications and productivity decision making in unreliable manufacturing systems," International Journal of Production Economics, Elsevier, vol. 129(1), pages 32-42, January.
    6. 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.
    7. Xia, Tangbin & Xi, Lifeng & Zhou, Xiaojun & Lee, Jay, 2012. "Dynamic maintenance decision-making for series–parallel manufacturing system based on MAM–MTW methodology," European Journal of Operational Research, Elsevier, vol. 221(1), pages 231-240.
    8. Berthaut, F. & Gharbi, A. & Dhouib, K., 2011. "Joint modified block replacement and production/inventory control policy for a failure-prone manufacturing cell," Omega, Elsevier, vol. 39(6), pages 642-654, December.
    9. Chakraborty, Tulika & Giri, B.C. & Chaudhuri, K.S., 2009. "Production lot sizing with process deterioration and machine breakdown under inspection schedule," Omega, Elsevier, vol. 37(2), pages 257-271, April.
    10. Hsu, Lie-Fern & Kuo, Shyanjaw, 1995. "Design of optimal maintenance policies based on on-line sampling plans," European Journal of Operational Research, Elsevier, vol. 86(2), pages 345-357, October.
    11. Sana, Shib Sankar, 2010. "An economic production lot size model in an imperfect production system," European Journal of Operational Research, Elsevier, vol. 201(1), pages 158-170, February.
    12. Liao, Gwo-Liang & Chen, Yen Hung & Sheu, Shey-Huei, 2009. "Optimal economic production quantity policy for imperfect process with imperfect repair and maintenance," European Journal of Operational Research, Elsevier, vol. 195(2), pages 348-357, June.
    13. Pearn, W.L. & Wu, Chien-Wei, 2007. "An effective decision making method for product acceptance," Omega, Elsevier, vol. 35(1), pages 12-21, February.
    14. 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.
    15. Sana, Shib Sankar, 2010. "A production-inventory model in an imperfect production process," European Journal of Operational Research, Elsevier, vol. 200(2), pages 451-464, January.
    16. Hajji, Adnene & Gharbi, Ali & Kenne, Jean-Pierre & Pellerin, Robert, 2011. "Production control and replenishment strategy with multiple suppliers," European Journal of Operational Research, Elsevier, vol. 208(1), pages 67-74, January.
    17. Jahangirian, Mohsen & Eldabi, Tillal & Naseer, Aisha & Stergioulas, Lampros K. & Young, Terry, 2010. "Simulation in manufacturing and business: A review," European Journal of Operational Research, Elsevier, vol. 203(1), pages 1-13, May.
    18. Bouslah, Bassem & Gharbi, Ali & Pellerin, Robert, 2013. "Joint optimal lot sizing and production control policy in an unreliable and imperfect manufacturing system," International Journal of Production Economics, Elsevier, vol. 144(1), pages 143-156.
    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. 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.
    2. 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.
    3. Hlioui, Rached & Gharbi, Ali & Hajji, Adnène, 2017. "Joint supplier selection, production and replenishment of an unreliable manufacturing-oriented supply chain," International Journal of Production Economics, Elsevier, vol. 187(C), pages 53-67.
    4. Bouslah, B. & Gharbi, A. & Pellerin, R., 2016. "Joint economic design of production, continuous sampling inspection and preventive maintenance of a deteriorating production system," International Journal of Production Economics, Elsevier, vol. 173(C), pages 184-198.
    5. 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).
    6. Dauzère-Pérès, Stéphane & Hassoun, Michael, 2020. "On the importance of variability when managing metrology capacity," European Journal of Operational Research, Elsevier, vol. 282(1), pages 267-276.
    7. Yihai He & Changchao Gu & Zhaoxiang Chen & Xiao Han, 2017. "Integrated predictive maintenance strategy for manufacturing systems by combining quality control and mission reliability analysis," International Journal of Production Research, Taylor & Francis Journals, vol. 55(19), pages 5841-5862, October.
    8. 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.
    9. 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).

    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. 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.
    2. Peymankar, Mahboobe & Dehghanian, Farzad & Ghiami, Yousef & Abolbashari, Mohammad Hassan, 2018. "The effects of contractual agreements on the economic production quantity model with machine breakdown," International Journal of Production Economics, Elsevier, vol. 201(C), pages 203-215.
    3. 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).
    4. Wee, Hui Ming & Widyadana, Gede Agus, 2013. "A production model for deteriorating items with stochastic preventive maintenance time and rework process with FIFO rule," Omega, Elsevier, vol. 41(6), pages 941-954.
    5. Kazaz, Burak & Sloan, Thomas W., 2013. "The impact of process deterioration on production and maintenance policies," European Journal of Operational Research, Elsevier, vol. 227(1), pages 88-100.
    6. Bouslah, Bassem & Gharbi, Ali & Pellerin, Robert, 2013. "Joint optimal lot sizing and production control policy in an unreliable and imperfect manufacturing system," International Journal of Production Economics, Elsevier, vol. 144(1), pages 143-156.
    7. Glock, Christoph H. & Grosse, Eric H., 2021. "The impact of controllable production rates on the performance of inventory systems: A systematic review of the literature," European Journal of Operational Research, Elsevier, vol. 288(3), pages 703-720.
    8. 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.
    9. Ata Allah Taleizadeh, 2018. "A constrained integrated imperfect manufacturing-inventory system with preventive maintenance and partial backordering," Annals of Operations Research, Springer, vol. 261(1), pages 303-337, February.
    10. Hlioui, Rached & Gharbi, Ali & Hajji, Adnène, 2015. "Replenishment, production and quality control strategies in three-stage supply chain," International Journal of Production Economics, Elsevier, vol. 166(C), pages 90-102.
    11. Ekin, Tahir, 2018. "Integrated maintenance and production planning with endogenous uncertain yield," Reliability Engineering and System Safety, Elsevier, vol. 179(C), pages 52-61.
    12. Pal, Brojeswar & Sana, Shib Sankar & Chaudhuri, Kripasindhu, 2014. "Joint pricing and ordering policy for two echelon imperfect production inventory model with two cycles," International Journal of Production Economics, Elsevier, vol. 155(C), pages 229-238.
    13. Chiu, Yuan-Shyi Peter & Chen, Yung-Chung & Lin, Hong-Dar & Chang, Huei-Hsin, 2014. "Combining an improved multi-delivery policy into a single-producer multi-retailer integrated inventory system with scrap in production," Economic Modelling, Elsevier, vol. 39(C), pages 163-167.
    14. Sarkar, Mitali & Sarkar, Biswajit, 2013. "An economic manufacturing quantity model with probabilistic deterioration in a production system," Economic Modelling, Elsevier, vol. 31(C), pages 245-252.
    15. Om Prakash & A.R. Roy & A. Goswami, 2014. "Stochastic manufacturing system with process deterioration and machine breakdown," International Journal of Systems Science, Taylor & Francis Journals, vol. 45(12), pages 2539-2551, December.
    16. Jiawen Hu & Zuhua Jiang & Hong Wang, 2016. "Preventive maintenance for a single-machine system under variable operational conditions," Journal of Risk and Reliability, , vol. 230(4), pages 391-404, August.
    17. Shaofu Du & Yujiao Zhu & Tengfei Nie & Haisuo Yu, 2018. "Loss-averse preferences in a two-echelon supply chain with yield risk and demand uncertainty," Operational Research, Springer, vol. 18(2), pages 361-388, July.
    18. Gour Chandra Mahata, 2017. "A production-inventory model with imperfect production process and partial backlogging under learning considerations in fuzzy random environments," Journal of Intelligent Manufacturing, Springer, vol. 28(4), pages 883-897, April.
    19. Chao Luo & Hiroyuki Okamura & Tadashi Dohi, 2016. "Optimal planning for open source software updates," Journal of Risk and Reliability, , vol. 230(1), pages 44-53, February.
    20. Paul, Sanjoy Kumar & Sarker, Ruhul & Essam, Daryl, 2014. "Real time disruption management for a two-stage batch production–inventory system with reliability considerations," European Journal of Operational Research, Elsevier, vol. 237(1), pages 113-128.

    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:eee:jomega:v:61:y:2016:i:c:p:110-126. See general information about how to correct material in RePEc.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: (Haili He). General contact details of provider: http://www.elsevier.com/wps/find/journaldescription.cws_home/375/description#description .

    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 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.

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

    IDEAS is a RePEc service hosted by the Research Division of the Federal Reserve Bank of St. Louis . RePEc uses bibliographic data supplied by the respective publishers.