IDEAS home Printed from https://ideas.repec.org/a/eee/jomega/v39y2011i6p642-654.html
   My bibliography  Save this article

Joint modified block replacement and production/inventory control policy for a failure-prone manufacturing cell

Author

Listed:
  • Berthaut, F.
  • Gharbi, A.
  • Dhouib, K.

Abstract

This paper considers a joint preventive maintenance (PM) and production/inventory control policy of an unreliable single machine, mono-product manufacturing cell with stochastic non-negligible corrective and preventive delays. The production/inventory control policy, which is based on the hedging point policy (HPP), consists in building and maintaining a safety stock of finished products in order to respond to demand and to avoid shortages during maintenance actions. Without considering the impact of preventive and corrective actions on the overall performance of the production system, most authors working in the reliability and maintainability domains confirm that the age-based preventive maintenance policy (ARP) outperforms the classical block-replacement policy (BRP). In order to reduce wastage incurred by the classical BRP, we consider a modified block replacement policy (MBRP), which consists in canceling a preventive maintenance action if the time elapsed since the last maintenance action exceeds a specified time threshold. The main objective of this paper is to determine the joint optimal policy that minimizes the overall cost, which is composed of corrective and preventive maintenance costs as well as inventory holding and backlog costs. A simulation model mimicking the dynamic and stochastic behavior of the manufacturing cell, based on more realistic considerations of the real behavior of industrial manufacturing cells, is proposed. Based on simulation results, the joint optimal MBRP/HPP parameters are obtained through a numerical approach that combines design of experiment, analysis of variance and response surface methodologies. The joint optimal MBRP/HPP policy is compared to classical joint ARP/HPP and BRP/HPP optimal policies, and the results show that the proposed MBRP/HPP outperforms the latter. Sensitivity analyses are also carried out in order to confirm the superiority of the proposed MBRP/HPP, and it is observed that for practitioners, the proposed joint MBRP/HPP offers not only cost savings, but is also easy to manage, as compared to the ARP/HPP policy.

Suggested Citation

  • Berthaut, F. & Gharbi, A. & Dhouib, K., 2011. "Joint modified block replacement and production/inventory control policy for a failure-prone manufacturing cell," Omega, Elsevier, vol. 39(6), pages 642-654, December.
    • Handle: RePEc:eee:jomega:v:39:y:2011:i:6:p:642-654
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0305-0483(11)00009-0
    Download Restriction: Full text for ScienceDirect subscribers only
    ---><---

    As the access to this document is restricted, you may want to search for a different version of it.

    References listed on IDEAS

    as
    1. Salameh, M. K. & Ghattas, R. E., 2001. "Optimal just-in-time buffer inventory for regular preventive maintenance," International Journal of Production Economics, Elsevier, vol. 74(1-3), pages 157-161, December.
    2. Hipkin, I. B. & De Cock, C., 2000. "TQM and BPR: lessons for maintenance management," Omega, Elsevier, vol. 28(3), pages 277-292, June.
    3. Pentico, David W. & Drake, Matthew J. & Toews, Carl, 2009. "The deterministic EPQ with partial backordering: A new approach," Omega, Elsevier, vol. 37(3), pages 624-636, June.
    4. Yang, Suh-Jenq & Yang, Dar-Li, 2010. "Minimizing the makespan on single-machine scheduling with aging effect and variable maintenance activities," Omega, Elsevier, vol. 38(6), pages 528-533, December.
    5. Chelbi, Anis & Ait-Kadi, Daoud, 2004. "Analysis of a production/inventory system with randomly failing production unit submitted to regular preventive maintenance," European Journal of Operational Research, Elsevier, vol. 156(3), pages 712-718, August.
    6. Savsar, Mehmet, 2006. "Effects of maintenance policies on the productivity of flexible manufacturing cells," Omega, Elsevier, vol. 34(3), pages 274-282, June.
    7. Chelbi, Anis & Ait-Kadi, Daoud, 2000. "Generalized inspection strategy for randomly failing systems subjected to random shocks," International Journal of Production Economics, Elsevier, vol. 64(1-3), pages 379-384, March.
    8. Gharbi, A. & Kenne, J.-P. & Beit, M., 2007. "Optimal safety stocks and preventive maintenance periods in unreliable manufacturing systems," International Journal of Production Economics, Elsevier, vol. 107(2), pages 422-434, June.
    9. Wang, Hongzhou, 2002. "A survey of maintenance policies of deteriorating systems," European Journal of Operational Research, Elsevier, vol. 139(3), pages 469-489, June.
    10. Gharbi, A. & Kenne, J. P., 2000. "Production and preventive maintenance rates control for a manufacturing system: An experimental design approach," International Journal of Production Economics, Elsevier, vol. 65(3), pages 275-287, May.
    11. Chakraborty, Tulika & Giri, B.C. & Chaudhuri, K.S., 2009. "Production lot sizing with process deterioration and machine breakdown under inspection schedule," Omega, Elsevier, vol. 37(2), pages 257-271, April.
    12. Chang, Hung-Chi & Ho, Chia-Huei, 2010. "Exact closed-form solutions for "optimal inventory model for items with imperfect quality and shortage backordering"," Omega, Elsevier, vol. 38(3-4), pages 233-237, June.
    13. Frank Proschan & T. A. Bray, 1965. "Optimum Redundancy Under Multiple Constraints," Operations Research, INFORMS, vol. 13(5), pages 800-814, October.
    14. Crespo Marquez, Adolfo & Gupta, Jatinder N.D., 2006. "Contemporary maintenance management: process, framework and supporting pillars," Omega, Elsevier, vol. 34(3), pages 313-326, June.
    15. Chen, Wen-Jinn, 2009. "Minimizing number of tardy jobs on a single machine subject to periodic maintenance," Omega, Elsevier, vol. 37(3), pages 591-599, June.
    16. Carnero Moya, M. Carmen, 2004. "The control of the setting up of a predictive maintenance programme using a system of indicators," Omega, Elsevier, vol. 32(1), pages 57-75, February.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Zhang, Qin & Fang, Zhigeng & Cai, Jiajia, 2021. "Extended block replacement policies with mission durations and maintenance triggering approaches," Reliability Engineering and System Safety, Elsevier, vol. 207(C).
    2. Jeang, Angus, 2012. "Simultaneous determination of production lot size and process parameters under process deterioration and process breakdown," Omega, Elsevier, vol. 40(6), pages 774-781.
    3. Om Prakash & A.R. Roy & A. Goswami, 2014. "Stochastic manufacturing system with process deterioration and machine breakdown," International Journal of Systems Science, Taylor & Francis Journals, vol. 45(12), pages 2539-2551, December.
    4. Assid, M. & Gharbi, A. & Dhouib, K., 2015. "Joint production and subcontracting planning of unreliable multi-facility multi-product production systems," Omega, Elsevier, vol. 50(C), pages 54-69.
    5. Ke, Hua & Yao, Kai, 2016. "Block replacement policy with uncertain lifetimes," Reliability Engineering and System Safety, Elsevier, vol. 148(C), pages 119-124.
    6. Hauck, Zsuzsanna & Vörös, József, 2015. "Lot sizing in case of defective items with investments to increase the speed of quality control," Omega, Elsevier, vol. 52(C), pages 180-189.
    7. 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.
    8. Dhouib, K. & Gharbi, A. & Ben Aziza, M.N., 2012. "Joint optimal production control/preventive maintenance policy for imperfect process manufacturing cell," International Journal of Production Economics, Elsevier, vol. 137(1), pages 126-136.
    9. S. Priyan & P. Manivannan, 2017. "Optimal inventory modeling of supply chain system involving quality inspection errors and fuzzy defective rate," OPSEARCH, Springer;Operational Research Society of India, vol. 54(1), pages 21-43, March.
    10. 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.

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Berthaut, F. & Gharbi, A. & Kenné, J.-P. & Boulet, J.-F., 2010. "Improved joint preventive maintenance and hedging point policy," International Journal of Production Economics, Elsevier, vol. 127(1), pages 60-72, September.
    2. Gharbi, A. & Kenne, J.-P. & Beit, M., 2007. "Optimal safety stocks and preventive maintenance periods in unreliable manufacturing systems," International Journal of Production Economics, Elsevier, vol. 107(2), pages 422-434, June.
    3. Dhouib, K. & Gharbi, A. & Ben Aziza, M.N., 2012. "Joint optimal production control/preventive maintenance policy for imperfect process manufacturing cell," International Journal of Production Economics, Elsevier, vol. 137(1), pages 126-136.
    4. Budai-Balke, G. & Dekker, R. & Nicolai, R.P., 2006. "A review of planning models for maintenance and production," Econometric Institute Research Papers EI 2006-44, Erasmus University Rotterdam, Erasmus School of Economics (ESE), Econometric Institute.
    5. Jeang, Angus, 2012. "Simultaneous determination of production lot size and process parameters under process deterioration and process breakdown," Omega, Elsevier, vol. 40(6), pages 774-781.
    6. Ishizaka, Alessio & Nemery, Philippe, 2014. "Assigning machines to incomparable maintenance strategies with ELECTRE-SORT," Omega, Elsevier, vol. 47(C), pages 45-59.
    7. 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.
    8. Hashemi, M. & Asadi, M. & Zarezadeh, S., 2020. "Optimal maintenance policies for coherent systems with multi-type components," Reliability Engineering and System Safety, Elsevier, vol. 195(C).
    9. Berrade, M.D. & Cavalcante, C.A.V. & Scarf, P.A., 2013. "Modelling imperfect inspection over a finite horizon," Reliability Engineering and System Safety, Elsevier, vol. 111(C), pages 18-29.
    10. 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.
    11. Souheil Ayed & Zied Hajej & Sadok Turki & Nidhal Rezg, 2017. "FPA method for optimal production planning under availability/degradation machine and subcontracting constraint," International Journal of Production Research, Taylor & Francis Journals, vol. 55(8), pages 2135-2148, April.
    12. Dimitrakos, T.D. & Kyriakidis, E.G., 2008. "A semi-Markov decision algorithm for the maintenance of a production system with buffer capacity and continuous repair times," International Journal of Production Economics, Elsevier, vol. 111(2), pages 752-762, February.
    13. Ramasesh, Ranga V., 2010. "Lot-sizing decisions under limited-time price incentives: A review," Omega, Elsevier, vol. 38(3-4), pages 118-135, June.
    14. A. Azadeh & M. Sheikhalishahi & S. Mortazavi & E. Ahmadi Jooghi, 2017. "Joint quality control and preventive maintenance strategy: a unique taguchi approach," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 8(1), pages 123-134, March.
    15. Gössinger, Ralf & Helmke, Hanna & Kaluzny, Michael, 2017. "Condition-based release of maintenance jobs in a decentralised production-maintenance system – An analysis of alternative stochastic approaches," International Journal of Production Economics, Elsevier, vol. 193(C), pages 528-537.
    16. Zequeira, Romulo I. & Valdes, Jose E. & Berenguer, Christophe, 2008. "Optimal buffer inventory and opportunistic preventive maintenance under random production capacity availability," International Journal of Production Economics, Elsevier, vol. 111(2), pages 686-696, February.
    17. Kenne, J.-P. & Gharbi, A. & Beit, M., 2007. "Age-dependent production planning and maintenance strategies in unreliable manufacturing systems with lost sale," European Journal of Operational Research, Elsevier, vol. 178(2), pages 408-420, April.
    18. 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.
    19. Bouvard, K. & Artus, S. & Bérenguer, C. & Cocquempot, V., 2011. "Condition-based dynamic maintenance operations planning & grouping. Application to commercial heavy vehicles," Reliability Engineering and System Safety, Elsevier, vol. 96(6), pages 601-610.
    20. Hsieh, Tsu-Pang & Dye, Chung-Yuan, 2012. "A note on "The EPQ with partial backordering and phase-dependent backordering rate"," Omega, Elsevier, vol. 40(1), pages 131-133, January.

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:jomega:v:39:y:2011:i:6:p:642-654. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: http://www.elsevier.com/wps/find/journaldescription.cws_home/375/description#description .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.