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Imperfect preventive maintenance optimization for flexible flowshop manufacturing cells considering sequence-dependent group scheduling

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  • Feng, Hanxin
  • Xi, Lifeng
  • Xiao, Lei
  • Xia, Tangbin
  • Pan, Ershun

Abstract

Flexible flowshop manufacturing cells (FFMCs) have been widely applied to achieve the efficiency of high-volume manufacturing for products of small-to-medium demand. In FFMCs, jobs from several groups are processed at several stages with the same route and group-varying machining conditions. This paper integrates imperfect preventive maintenance (PM) and sequence-dependent group scheduling (GS) in FFMCs. A machine-level model is developed to describe machine reliability evolution under group-varying conditions. A system-level model is proposed to simultaneously obtain the planning of PM and GS by minimizing PM cost, minimal repair cost, and job tardiness cost in FFMCs. To solve the model, a simulated annealing embedded genetic algorithm (SAGA) is developed. Experiments show that the PM policy obtained by our proposed model can remarkably save cost when compared with three other types of policies. Further experiments present that the integer-key based chromosome representation of SAGA excels a random-key based representation, and SAGA outperforms SA and GA in terms of both the solution quality and robustness.

Suggested Citation

  • 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.
    • Handle: RePEc:eee:reensy:v:176:y:2018:i:c:p:218-229
    DOI: 10.1016/j.ress.2018.04.004
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    2. Shuaipeng Yuan & Tieke Li & Bailin Wang, 2021. "A discrete differential evolution algorithm for flow shop group scheduling problem with sequence-dependent setup and transportation times," Journal of Intelligent Manufacturing, Springer, vol. 32(2), pages 427-439, February.
    3. 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).
    4. Sinisterra, Wilfrido Quiñones & Cavalcante, Cristiano Alexandre Virgínio, 2020. "An integrated model of production scheduling and inspection planning for resumable jobs," International Journal of Production Economics, Elsevier, vol. 227(C).
    5. An, Xiangxin & Si, Guojin & Xia, Tangbin & Wang, Dong & Pan, Ershun & Xi, Lifeng, 2023. "An energy-efficient collaborative strategy of maintenance planning and production scheduling for serial-parallel systems under time-of-use tariffs," Applied Energy, Elsevier, vol. 336(C).
    6. 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.
    7. Xiangxin An & Guojin Si & Tangbin Xia & Qinming Liu & Yaping Li & Rui Miao, 2022. "Operation and Maintenance Optimization for Manufacturing Systems with Energy Management," Energies, MDPI, vol. 15(19), pages 1-19, October.
    8. 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).
    9. Faddoul, R. & Raphael, W. & Chateauneuf, A., 2018. "Maintenance optimization of series systems subject to reliability constraints," Reliability Engineering and System Safety, Elsevier, vol. 180(C), pages 179-188.
    10. Ghorbanzadeh, Masoumeh & Ranjbar, Mohammad, 2023. "Energy-aware production scheduling in the flow shop environment under sequence-dependent setup times, group scheduling and renewable energy constraints," European Journal of Operational Research, Elsevier, vol. 307(2), pages 519-537.
    11. Wenzhu Liao & Tong Wang, 2018. "Promoting Green and Sustainability: A Multi-Objective Optimization Method for the Job-Shop Scheduling Problem," Sustainability, MDPI, vol. 10(11), pages 1-19, November.
    12. 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).

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