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Joint production and major maintenance planning policy of a manufacturing system with deteriorating quality

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  • Rivera-Gómez, Héctor
  • Gharbi, Ali
  • Kenné, Jean Pierre

Abstract

We investigate the simultaneous production planning and quality control problem for an unreliable single machine manufacturing system responding to a single product type demand. The machine is subject to deteriorations, and their effect is observed mainly on the rate of defectives, which increases continuously over time. Due to the uncertainty caused by failures, the machine may not meet long-term demand, and an overhaul can be conducted in order to counter the effect of the deterioration. The main objective of this study is to simultaneously determine the optimal production plan and overhaul schedule for the analyzed manufacturing system, in order to minimize the total cost, comprising the inventory, backlog, repair and overhaul cost, over an infinite planning horizon. A stochastic dynamic programming model is proposed, in which a numerical scheme is adopted to solve the optimality condition equations. It is observed that the optimal control policy is described by a machine deterioration-dependent hedging point policy (MDDHPP). To accurately approximate the related control parameters, a simulation optimization approach based on design of experiments, simulation modeling and response surface methodology is applied. The results obtained provide a better understanding about the influence of the deterioration of quality in the production and overhaul policies. A numerical example and an extensive sensitivity analysis are conducted, and show the robust behavior and usefulness of the policy obtained.

Suggested Citation

  • Rivera-Gómez, Héctor & Gharbi, Ali & Kenné, Jean Pierre, 2013. "Joint production and major maintenance planning policy of a manufacturing system with deteriorating quality," International Journal of Production Economics, Elsevier, vol. 146(2), pages 575-587.
    • Handle: RePEc:eee:proeco:v:146:y:2013:i:2:p:575-587
    DOI: 10.1016/j.ijpe.2013.08.006
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    Cited by:

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    2. Kort, Peter & Lavrutich, Maria & Nunes, Cláudia & Oliveira, Carlos, 2023. "Preventive investment, malfunctions and liability," International Journal of Production Economics, Elsevier, vol. 263(C).
    3. Hlioui, Rached & Gharbi, Ali & Hajji, Adnène, 2017. "Joint supplier selection, production and replenishment of an unreliable manufacturing-oriented supply chain," International Journal of Production Economics, Elsevier, vol. 187(C), pages 53-67.
    4. Bouslah, B. & Gharbi, A. & Pellerin, R., 2016. "Joint economic design of production, continuous sampling inspection and preventive maintenance of a deteriorating production system," International Journal of Production Economics, Elsevier, vol. 173(C), pages 184-198.
    5. Rivera-Gómez, Héctor & Gharbi, Ali & Kenné, Jean-Pierre & Montaño-Arango, Oscar & Hernandez-Gress, Eva Selene, 2016. "Production control problem integrating overhaul and subcontracting strategies for a quality deteriorating manufacturing system," International Journal of Production Economics, Elsevier, vol. 171(P1), pages 134-150.
    6. Yihai He & Changchao Gu & Zhaoxiang Chen & Xiao Han, 2017. "Integrated predictive maintenance strategy for manufacturing systems by combining quality control and mission reliability analysis," International Journal of Production Research, Taylor & Francis Journals, vol. 55(19), pages 5841-5862, October.
    7. Georgios K. Koulinas & Panagiotis D. Paraschos & Dimitrios E. Koulouriotis, 2024. "A machine learning framework for explainable knowledge mining and production, maintenance, and quality control optimization in flexible circular manufacturing systems," Flexible Services and Manufacturing Journal, Springer, vol. 36(3), pages 737-759, September.

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