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Joint optimization of production scheduling and machine group preventive maintenance

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  • Xiao, Lei
  • Song, Sanling
  • Chen, Xiaohui
  • Coit, David W.

Abstract

Joint optimization models were developed combining group preventive maintenance of a series system and production scheduling. In this paper, we propose a joint optimization model to minimize the total cost including production cost, preventive maintenance cost, minimal repair cost for unexpected failures and tardiness cost. The total cost depends on both the production process and the machine maintenance plan associated with reliability. For the problems addressed in this research, any machine unavailability leads to system downtime. Therefore, it is important to optimize the preventive maintenance of machines because their performance impacts the collective production processing associated with all machines. Too lengthy preventive maintenance intervals may be associated with low scheduled machine maintenance cost, but may incur expensive costs for unplanned failure due to low machine reliability. Alternatively, too frequent preventive maintenance activities may achieve the desired high reliability machines, but unacceptably high scheduled maintenance cost. Additionally, product scheduling plans affect tardiness and maintenance cost. Two results are obtained when solving the problem; the optimal group preventive maintenance interval for machines, and the assignment of each job, including the corresponding start time and completion time. To solve this non-deterministic polynomial-time problem, random keys genetic algorithms are used, and a numerical example is solved to illustrate the proposed model.

Suggested Citation

  • Xiao, Lei & Song, Sanling & Chen, Xiaohui & Coit, David W., 2016. "Joint optimization of production scheduling and machine group preventive maintenance," Reliability Engineering and System Safety, Elsevier, vol. 146(C), pages 68-78.
    • Handle: RePEc:eee:reensy:v:146:y:2016:i:c:p:68-78
    DOI: 10.1016/j.ress.2015.10.013
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    References listed on IDEAS

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    Cited by:

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    4. Xia, Tangbin & Dong, Yifan & Xiao, Lei & Du, Shichang & Pan, Ershun & Xi, Lifeng, 2018. "Recent advances in prognostics and health management for advanced manufacturing paradigms," Reliability Engineering and System Safety, Elsevier, vol. 178(C), pages 255-268.
    5. Wang, Hai-Kun & Li, Yan-Feng & Huang, Hong-Zhong & Jin, Tongdan, 2017. "Near-extreme system condition and near-extreme remaining useful time for a group of products," Reliability Engineering and System Safety, Elsevier, vol. 162(C), pages 103-110.
    6. Rokhforoz, Pegah & Gjorgiev, Blazhe & Sansavini, Giovanni & Fink, Olga, 2021. "Multi-agent maintenance scheduling based on the coordination between central operator and decentralized producers in an electricity market," Reliability Engineering and System Safety, Elsevier, vol. 210(C).
    7. Shen, Yilan & Zhang, Xi & Shi, Leyuan, 2022. "Joint optimization of production and maintenance for a serial–parallel hybrid two-stage production system," Reliability Engineering and System Safety, Elsevier, vol. 226(C).
    8. Hongming Zhou & Sufen Wang & Faqun Qi & Shun Gao, 2022. "Maintenance modeling and operation parameters optimization for complex production line under reliability constraints," Annals of Operations Research, Springer, vol. 311(1), pages 507-523, April.
    9. Hu, Yang & Miao, Xuewen & Si, Yong & Pan, Ershun & Zio, Enrico, 2022. "Prognostics and health management: A review from the perspectives of design, development and decision," Reliability Engineering and System Safety, Elsevier, vol. 217(C).
    10. Xiao, Lei & Zhang, Xinghui & Tang, Junxuan & Zhou, Yaqin, 2020. "Joint optimization of opportunistic maintenance and production scheduling considering batch production mode and varying operational conditions," Reliability Engineering and System Safety, Elsevier, vol. 202(C).
    11. Petchrompo, Sanyapong & Parlikad, Ajith Kumar, 2019. "A review of asset management literature on multi-asset systems," Reliability Engineering and System Safety, Elsevier, vol. 181(C), pages 181-201.
    12. Jiang, Junwei & An, Youjun & Dong, Yuanfa & Hu, Jiawen & Li, Yinghe & Zhao, Ziye, 2023. "Integrated optimization of non-permutation flow shop scheduling and maintenance planning with variable processing speed," Reliability Engineering and System Safety, Elsevier, vol. 234(C).
    13. Zeng, Zhiguo & Barros, Anne & Coit, David, 2023. "Dependent failure behavior modeling for risk and reliability: A systematic and critical literature review," Reliability Engineering and System Safety, Elsevier, vol. 239(C).
    14. Ye, Zhenggeng & Cai, Zhiqiang & Yang, Hui & Si, Shubin & Zhou, Fuli, 2023. "Joint optimization of maintenance and quality inspection for manufacturing networks based on deep reinforcement learning," Reliability Engineering and System Safety, Elsevier, vol. 236(C).
    15. An, Xiangxin & Si, Guojin & Xia, Tangbin & Wang, Dong & Pan, Ershun & Xi, Lifeng, 2023. "An energy-efficient collaborative strategy of maintenance planning and production scheduling for serial-parallel systems under time-of-use tariffs," Applied Energy, Elsevier, vol. 336(C).
    16. uit het Broek, Michiel A.J. & Teunter, Ruud H. & de Jonge, Bram & Veldman, Jasper, 2021. "Joint condition-based maintenance and condition-based production optimization," Reliability Engineering and System Safety, Elsevier, vol. 214(C).
    17. Xiufang Zhang & Tangbin Xia & Ershun Pan & Yuqing Li, 2022. "Integrated optimization on production scheduling and imperfect preventive maintenance considering multi-degradation and learning-forgetting effects," Flexible Services and Manufacturing Journal, Springer, vol. 34(2), pages 451-482, June.
    18. Xia, Tangbin & Si, Guojin & Shi, Guo & Zhang, Kaigan & Xi, Lifeng, 2022. "Optimal selective maintenance scheduling for series–parallel systems based on energy efficiency optimization," Applied Energy, Elsevier, vol. 314(C).
    19. Aseem K. Mishra & Divya Shrivastava & Devesh Tarasia & Abdur Rahim, 2022. "Joint optimization of production scheduling and group preventive maintenance planning in multi-machine systems," Annals of Operations Research, Springer, vol. 316(1), pages 401-444, September.
    20. de Jonge, Bram & Scarf, Philip A., 2020. "A review on maintenance optimization," European Journal of Operational Research, Elsevier, vol. 285(3), pages 805-824.
    21. Edson Ruschel & Eduardo Alves Portela Santos & Eduardo de Freitas Rocha Loures, 2020. "Establishment of maintenance inspection intervals: an application of process mining techniques in manufacturing," Journal of Intelligent Manufacturing, Springer, vol. 31(1), pages 53-72, January.
    22. Feng, Hanxin & Xi, Lifeng & Xiao, Lei & Xia, Tangbin & Pan, Ershun, 2018. "Imperfect preventive maintenance optimization for flexible flowshop manufacturing cells considering sequence-dependent group scheduling," Reliability Engineering and System Safety, Elsevier, vol. 176(C), pages 218-229.
    23. Bożena Zwolińska & Jakub Wiercioch, 2022. "Selection of Maintenance Strategies for Machines in a Series-Parallel System," Sustainability, MDPI, vol. 14(19), pages 1-20, September.

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