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Coordinating production, inspection and maintenance decisions in a stochastic manufacturing system with deterioration failures

Author

Listed:
  • A. S. Xanthopoulos

    (Democritus University of Thrace)

  • S. Vlastos

    (Democritus University of Thrace)

  • D. E. Koulouriotis

    (Democritus University of Thrace)

Abstract

We examine a manufacturing system that operates under an (s, S) or base stock production control policy. The system is subjected to periodic inspections to determine its deterioration stage. Based on that information, it is decided whether to maintain the system or not by a threshold-type policy. The system breaks down if it experiences a degradation at the last deterioration stage. At that time, a repair is initiated to restore the system to the good-as-new state. We develop Markov chain models of the examined system and derive mathematical expressions for a series of relevant performance metrics. We define an expected cost function that includes production, inventory, lost sales, repair, inspection, and maintenance costs. Furthermore, this research examines numerically the properties of the cost function and proposes a local search procedure for finding optimal control parameters in respect to minimizing the total cost. A series of numerical experiments is conducted in order to compare alternative production/inspection/maintenance policies under varying system parameters. The performance of the proposed local search heuristic is also evaluated by comparing it with an exhaustive search procedure. Based on the experimental findings, this research provides insights regarding best production/inspection/maintenance control practices.

Suggested Citation

  • A. S. Xanthopoulos & S. Vlastos & D. E. Koulouriotis, 2022. "Coordinating production, inspection and maintenance decisions in a stochastic manufacturing system with deterioration failures," Operational Research, Springer, vol. 22(5), pages 5707-5732, November.
    • Handle: RePEc:spr:operea:v:22:y:2022:i:5:d:10.1007_s12351-022-00715-z
    DOI: 10.1007/s12351-022-00715-z
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    References listed on IDEAS

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    1. Sayyideh Mehri Mousavi & Hesam Shams & Shahrzad Ahmadi, 2017. "Simultaneous optimization of repair and control-limit policy in condition-based maintenance," Journal of Intelligent Manufacturing, Springer, vol. 28(1), pages 245-254, January.
    2. Xanthopoulos, A.S. & Koulouriotis, D.E. & Botsaris, P.N., 2015. "Single-stage Kanban system with deterioration failures and condition-based preventive maintenance," Reliability Engineering and System Safety, Elsevier, vol. 142(C), pages 111-122.
    3. Peng, Hao & van Houtum, Geert-Jan, 2016. "Joint optimization of condition-based maintenance and production lot-sizing," European Journal of Operational Research, Elsevier, vol. 253(1), pages 94-107.
    4. Koutras, V.P. & Malefaki, S. & Platis, A.N., 2017. "Optimization of the dependability and performance measures of a generic model for multi-state deteriorating systems under maintenance," Reliability Engineering and System Safety, Elsevier, vol. 166(C), pages 73-86.
    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. Renqian Zhang & Xuefang Sun, 2018. "Integrated Production-Delivery Lot Sizing Model with Limited Production Capacity and Transportation Cost considering Overtime Work and Maintenance Time," Mathematical Problems in Engineering, Hindawi, vol. 2018, pages 1-10, April.
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    Cited by:

    1. C. K. Sivashankari & R. Valarmathi, 2023. "Optimal pricing and production lot-size policies in imperfect production system with price-sensitive demand, reworking, scrap, and sales return," Operational Research, Springer, vol. 23(3), pages 1-28, September.

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