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Optimal economic production quantity policy for imperfect process with imperfect repair and maintenance

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  • Liao, Gwo-Liang
  • Chen, Yen Hung
  • Sheu, Shey-Huei

Abstract

This study integrates maintenance and production programs with the economic production quantity (EPQ) model for an imperfect process involving a deteriorating production system with increasing hazard rate: imperfect repair and rework upon failure (out of control state). The imperfect repair performs some restorations and restores the system to an operating state (in-control state), but leaves its failure until perfect preventive maintenance (PM) is performed. There are two types of PM, namely imperfect PM and perfect PM. The probability that perfect PM is performed depends on the number of imperfect maintenance operations performed since the last renewal cycle. Mathematical formulas are obtained for deriving the expected total cost. For the EPQ model, the optimum run time, which minimizes the total cost, is discussed. Various special cases are considered, including the maintenance learning effect. Finally, a numerical example is presented to illustrate the effects of PM, setup, breakdown and holding costs.

Suggested Citation

  • 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.
    • Handle: RePEc:eee:ejores:v:195:y:2009:i:2:p:348-357
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    Cited by:

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    2. 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).
    3. 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.
    4. DeCarolis, Joseph & Daly, Hannah & Dodds, Paul & Keppo, Ilkka & Li, Francis & McDowall, Will & Pye, Steve & Strachan, Neil & Trutnevyte, Evelina & Usher, Will & Winning, Matthew & Yeh, Sonia & Zeyring, 2017. "Formalizing best practice for energy system optimization modelling," Applied Energy, Elsevier, vol. 194(C), pages 184-198.
    5. 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.
    6. 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.
    7. 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.
    8. K.Y. Kung & Y.D. Huang & H.M. Wee & Y. Daryanto, 2019. "Production-Inventory System for Deteriorating Items with Machine Breakdown, Inspection, and Partial Backordering," Mathematics, MDPI, vol. 7(7), pages 1-26, July.
    9. 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.
    10. Le, Minh Duc & Tan, Cher Ming, 2013. "Optimal maintenance strategy of deteriorating system under imperfect maintenance and inspection using mixed inspectionscheduling," Reliability Engineering and System Safety, Elsevier, vol. 113(C), pages 21-29.
    11. Sarkar, Biswajit & Saren, Sharmila, 2016. "Product inspection policy for an imperfect production system with inspection errors and warranty cost," European Journal of Operational Research, Elsevier, vol. 248(1), pages 263-271.
    12. Al-Salamah, Muhammad, 2019. "Economic production quantity in an imperfect manufacturing process with synchronous and asynchronous flexible rework rates," Operations Research Perspectives, Elsevier, vol. 6(C).
    13. 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.
    14. Zhang, Fengxia & Shen, Jingyuan & Ma, Yizhong, 2020. "Optimal maintenance policy considering imperfect repairs and non-constant probabilities of inspection errors," Reliability Engineering and System Safety, Elsevier, vol. 193(C).
    15. 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.
    16. R. Udayakumar & S. Priyan & Mandeep Mittal & Anuwat Jirawattanapanit & Grienggrai Rajchakit & Pramet Kaewmesri, 2022. "A Sustainable Production Scheduling with Backorders under Different Forms of Rework Process and Green Investment," Sustainability, MDPI, vol. 14(24), pages 1-38, December.
    17. Taleizadeh, Ata Allah & Cárdenas-Barrón, Leopoldo Eduardo & Mohammadi, Babak, 2014. "A deterministic multi product single machine EPQ model with backordering, scraped products, rework and interruption in manufacturing process," International Journal of Production Economics, Elsevier, vol. 150(C), pages 9-27.
    18. Shen, Jingyuan & Cui, Lirong & Ma, Yizhong, 2019. "Availability and optimal maintenance policy for systems degrading in dynamic environments," European Journal of Operational Research, Elsevier, vol. 276(1), pages 133-143.
    19. 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.

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