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Flexible job shop scheduling with preventive maintenance consideration

Author

Listed:
  • Michael Mario Wocker

    (TU Dortmund University
    BMW Group)

  • Frederik Ferid Ostermeier

    (TU Dortmund University
    BMW Group)

  • Tobias Wanninger

    (Technical University of Munich)

  • Ronny Zwinkau

    (TU Dortmund University)

  • Jochen Deuse

    (TU Dortmund University
    University of Technology Sydney)

Abstract

In highly automated manufacturing systems running 24/7, preventive maintenance activities need to be executed during production times. Flexible job shops with several identical machines generally bear the potential to compensate temporary machine unavailability times caused by preventive maintenance without a considerable increase of the makespan due to machine paralleling. However, this requires sophisticated scheduling of manufacturing jobs and the assignment of maintenance activities over the scheduling horizon. This work, therefore, introduces a mixed-integer program that models both job scheduling and maintenance activity assignment. A local search algorithm is developed to solve both problems in an integrated way. Numerical studies are carried out based on data from a real flexible job shop in the automotive industry with 78 machines and four products. The results show that joint job scheduling and maintenance activity assignment is required to obtain a makespan similar to the makespan without maintenance consideration. Non-sophisticated scheduling of maintenance windows can increase the makespan by more than 20 percentage points compared to sophisticated scheduling. Besides, we show that only a limited amount of maintenance activities can be compensated and that higher unavailability times will inevitably lead to detrimental effects on the makespan unless maintenance worker capacity is increased.

Suggested Citation

  • Michael Mario Wocker & Frederik Ferid Ostermeier & Tobias Wanninger & Ronny Zwinkau & Jochen Deuse, 2024. "Flexible job shop scheduling with preventive maintenance consideration," Journal of Intelligent Manufacturing, Springer, vol. 35(4), pages 1517-1539, April.
    • Handle: RePEc:spr:joinma:v:35:y:2024:i:4:d:10.1007_s10845-023-02114-3
    DOI: 10.1007/s10845-023-02114-3
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    References listed on IDEAS

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    1. Seyed Habib A. Rahmati & Abbas Ahmadi & Kannan Govindan, 2018. "A novel integrated condition-based maintenance and stochastic flexible job shop scheduling problem: simulation-based optimization approach," Annals of Operations Research, Springer, vol. 269(1), pages 583-621, October.
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    4. Zribi, N. & El Kamel, A. & Borne, P., 2008. "Minimizing the makespan for the MPM job-shop with availability constraints," International Journal of Production Economics, Elsevier, vol. 112(1), pages 151-160, March.
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    6. Karin Thörnblad & Ann-Brith Strömberg & Michael Patriksson & Torgny Almgren, 2015. "Scheduling optimisation of a real flexible job shop including fixture availability and preventive maintenance," European Journal of Industrial Engineering, Inderscience Enterprises Ltd, vol. 9(1), pages 126-145.
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