Joint optimisation of production, maintenance and quality for batch production system subject to varying operational conditions

This paper considers the integration problem of production, maintenance and quality for a capacitated lot-sizing production system subject to deterioration. The effects of varying operational conditions from batch to batch on system reliability and product quality are modelled by proportional hazard...

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Published inInternational journal of production research Vol. 57; no. 24; pp. 7552 - 7566
Main Authors Wang, Lin, Lu, Zhiqiang, Han, Xiaole
Format Journal Article
LanguageEnglish
Published London Taylor & Francis 17.12.2019
Taylor & Francis LLC
Subjects
Batch production
Deterioration
Economic models
Failure rates
Genetic algorithms
Inspection
operational condition
Optimization
Preventive maintenance
production planning
productivity and quality integration
Reliability aspects
small batch production
Statistical models
System reliability
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Abstract This paper considers the integration problem of production, maintenance and quality for a capacitated lot-sizing production system subject to deterioration. The effects of varying operational conditions from batch to batch on system reliability and product quality are modelled by proportional hazards models, resulting in non-monotonic failure rate and defect rate. After each batch production, imperfect preventive maintenance (PM) is determined to mitigate the system deterioration, and inspection is taken to sort nonconforming items in the finished goods. Once the cumulative number of nonconforming items exceeds a predetermined threshold, an overhaul is performed to renew the system. An integrated model for optimising production plan, PM plan and overhaul strategy is developed to minimise the total cost while satisfying all product demands. A genetic algorithm is proposed to solve the integrated model efficiently. Numerical results validate the rationality of the model with varying operational conditions consideration and its applicability in economic benefits.
AbstractList This paper considers the integration problem of production, maintenance and quality for a capacitated lot-sizing production system subject to deterioration. The effects of varying operational conditions from batch to batch on system reliability and product quality are modelled by proportional hazards models, resulting in non-monotonic failure rate and defect rate. After each batch production, imperfect preventive maintenance (PM) is determined to mitigate the system deterioration, and inspection is taken to sort nonconforming items in the finished goods. Once the cumulative number of nonconforming items exceeds a predetermined threshold, an overhaul is performed to renew the system. An integrated model for optimising production plan, PM plan and overhaul strategy is developed to minimise the total cost while satisfying all product demands. A genetic algorithm is proposed to solve the integrated model efficiently. Numerical results validate the rationality of the model with varying operational conditions consideration and its applicability in economic benefits.
Author Lu, Zhiqiang
Han, Xiaole
Wang, Lin
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  givenname: Xiaole
  surname: Han
  fullname: Han, Xiaole
  organization: School of Mechanical Engineering, Tongji University
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SubjectTerms Batch production
Deterioration
Economic models
Failure rates
Genetic algorithms
Inspection
operational condition
Optimization
Preventive maintenance
production planning
productivity and quality integration
Reliability aspects
small batch production
Statistical models
System reliability
Title Joint optimisation of production, maintenance and quality for batch production system subject to varying operational conditions
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