IDEAS home Printed from https://ideas.repec.org/a/eee/reensy/v199y2020ics0951832019309251.html
   My bibliography  Save this article

Joint production control and maintenance policy for a serial system with quality deterioration and stochastic demand

Author

Listed:
  • Wang, Lin
  • Lu, Zhiqiang
  • Ren, Yifei

Abstract

We consider a serial production system subject to stochastic deterioration with usage. Machines in the system will suffer quality failures and produce non-conforming items when they reach the out-of-control state. Non-conforming items transferred into the downstream machines may accelerate their deterioration process. Inspection is performed on the system to detect the state of all machines before starting each production lot. The predictive maintenance policy based on the predictive failure probability of each machine and the production control policy based on the target service level are proposed to meet the dynamic stochastic demand every period. Moreover, an opportunistic maintenance policy is considered to address the stochastic dependency and economic dependency in the system. An integrated model of production, quality and maintenance is developed to minimize the total cost. The optimal joint policy of the model is obtained by a simulation-based optimization method. Numerical experiments validate the advantages of our model in terms of cost savings and service improvement.

Suggested Citation

  • 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).
    • Handle: RePEc:eee:reensy:v:199:y:2020:i:c:s0951832019309251
    DOI: 10.1016/j.ress.2020.106918
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0951832019309251
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.ress.2020.106918?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    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. Zied Hajej & Nidhal Rezg & Ali Gharbi, 2018. "Quality issue in forecasting problem of production and maintenance policy for production unit," International Journal of Production Research, Taylor & Francis Journals, vol. 56(18), pages 6147-6163, September.
    2. Robin P. Nicolai & Rommert Dekker, 2008. "Optimal Maintenance of Multi-component Systems: A Review," Springer Series in Reliability Engineering, in: Complex System Maintenance Handbook, chapter 11, pages 263-286, Springer.
    3. Linkan Bian & Nagi Gebraeel, 2014. "Stochastic modeling and real-time prognostics for multi-component systems with degradation rate interactions," IISE Transactions, Taylor & Francis Journals, vol. 46(5), pages 470-482.
    4. James H. Bookbinder & Jin-Yan Tan, 1988. "Strategies for the Probabilistic Lot-Sizing Problem with Service-Level Constraints," Management Science, INFORMS, vol. 34(9), pages 1096-1108, September.
    5. 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.
    6. Fakher, Hossein Beheshti & Nourelfath, Mustapha & Gendreau, Michel, 2018. "Integrating production, maintenance and quality: A multi-period multi-product profit-maximization model," Reliability Engineering and System Safety, Elsevier, vol. 170(C), pages 191-201.
    7. Tempelmeier, Horst, 2007. "On the stochastic uncapacitated dynamic single-item lotsizing problem with service level constraints," European Journal of Operational Research, Elsevier, vol. 181(1), pages 184-194, August.
    8. Cheng, Guo Qing & Zhou, Bing Hai & Li, Ling, 2018. "Integrated production, quality control and condition-based maintenance for imperfect production systems," Reliability Engineering and System Safety, Elsevier, vol. 175(C), pages 251-264.
    9. Kenné, Jean-Pierre & Gharbi, Ali, 2018. "Production and replacement policies for a deteriorating manufacturing system under random demand and qualityAuthor-Name: Ouaret, Samir," European Journal of Operational Research, Elsevier, vol. 264(2), pages 623-636.
    10. Lin Wang & Zhiqiang Lu & Xiaole Han, 2019. "Joint optimisation of production, maintenance and quality for batch production system subject to varying operational conditions," International Journal of Production Research, Taylor & Francis Journals, vol. 57(24), pages 7552-7566, December.
    11. Bouslah, Bassem & Gharbi, Ali & Pellerin, Robert, 2018. "Joint production, quality and maintenance control of a two-machine line subject to operation-dependent and quality-dependent failures," International Journal of Production Economics, Elsevier, vol. 195(C), pages 210-226.
    12. Van Horenbeek, Adriaan & Pintelon, Liliane, 2013. "A dynamic predictive maintenance policy for complex multi-component systems," Reliability Engineering and System Safety, Elsevier, vol. 120(C), pages 39-50.
    13. 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.
    14. M Ben-Daya & M Makhdoum, 1998. "Integrated production and quality model under various preventive maintenance policies," Journal of the Operational Research Society, Palgrave Macmillan;The OR Society, vol. 49(8), pages 840-853, August.
    15. Do, Phuc & Voisin, Alexandre & Levrat, Eric & Iung, Benoit, 2015. "A proactive condition-based maintenance strategy with both perfect and imperfect maintenance actions," Reliability Engineering and System Safety, Elsevier, vol. 133(C), pages 22-32.
    16. Lu, Biao & Zhou, Xiaojun, 2017. "Opportunistic preventive maintenance scheduling for serial-parallel multistage manufacturing systems with multiple streams of deterioration," Reliability Engineering and System Safety, Elsevier, vol. 168(C), pages 116-127.
    17. Nourelfath, Mustapha & Nahas, Nabil & Ben-Daya, Mohamed, 2016. "Integrated preventive maintenance and production decisions for imperfect processes," Reliability Engineering and System Safety, Elsevier, vol. 148(C), pages 21-31.
    18. Sana, Shib Sankar, 2010. "An economic production lot size model in an imperfect production system," European Journal of Operational Research, Elsevier, vol. 201(1), pages 158-170, February.
    19. Xia, Tangbin & Jin, Xiaoning & Xi, Lifeng & Ni, Jun, 2015. "Production-driven opportunistic maintenance for batch production based on MAM–APB scheduling," European Journal of Operational Research, Elsevier, vol. 240(3), pages 781-790.
    20. Jahangirian, Mohsen & Eldabi, Tillal & Naseer, Aisha & Stergioulas, Lampros K. & Young, Terry, 2010. "Simulation in manufacturing and business: A review," European Journal of Operational Research, Elsevier, vol. 203(1), pages 1-13, May.
    21. Abdelhakim Khatab & Claver Diallo & El-Houssaine Aghezzaf & Uday Venkatadri, 2019. "Integrated production quality and condition-based maintenance optimisation for a stochastically deteriorating manufacturing system," International Journal of Production Research, Taylor & Francis Journals, vol. 57(8), pages 2480-2497, April.
    22. 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.
    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. Tambe, Pravin P. & Kulkarni, Makarand S., 2022. "A reliability based integrated model of maintenance planning with quality control and production decision for improving operational performance," Reliability Engineering and System Safety, Elsevier, vol. 226(C).
    2. 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).
    3. Ning, Ru & Wang, Xiaoyue & Zhao, Xian & Li, Ziyue, 2024. "Joint optimization of preventive maintenance and triggering mechanism for k-out-of-n: F systems with protective devices based on periodic inspection," Reliability Engineering and System Safety, Elsevier, vol. 251(C).
    4. Barlow, E. & Bedford, T. & Revie, M. & Tan, J. & Walls, L., 2021. "A performance-centred approach to optimising maintenance of complex systems," European Journal of Operational Research, Elsevier, vol. 292(2), pages 579-595.
    5. Boumallessa, Zeineb & Chouikhi, Houssam & Elleuch, Mounir & Bentaher, Hatem, 2023. "Modeling and optimizing the maintenance schedule using dynamic quality and machine condition monitors in an unreliable single production system," Reliability Engineering and System Safety, Elsevier, vol. 235(C).
    6. Rokhforoz, Pegah & Fink, Olga, 2022. "Maintenance scheduling of manufacturing systems based on optimal price of the network," Reliability Engineering and System Safety, Elsevier, vol. 217(C).
    7. Zhang, Chengjie & Qi, Faqun & Zhang, Ning & Li, Yong & Huang, Hongzhong, 2022. "Maintenance policy optimization for multi-component systems considering dynamic importance of components," Reliability Engineering and System Safety, Elsevier, vol. 226(C).
    8. 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).
    9. Xia, Tangbin & Cao, Lei & Xu, Yuhui & Zhang, Kaigan & Chen, Zhen & Pan, Ershun & Xi, Lifeng, 2024. "Multi-level maintenance and inventory joint optimization for a k-out-of-n hyper-system considering the selection of suppliers with incentive discount policies," Reliability Engineering and System Safety, Elsevier, vol. 241(C).
    10. Han, Xiao & Wang, Zili & Xie, Min & He, Yihai & Li, Yao & Wang, Wenzhuo, 2021. "Remaining useful life prediction and predictive maintenance strategies for multi-state manufacturing systems considering functional dependence," Reliability Engineering and System Safety, Elsevier, vol. 210(C).
    11. Azimpoor, Samareh & Taghipour, Sharareh, 2021. "Joint inspection and product quality optimization for a system with delayed failure," Reliability Engineering and System Safety, Elsevier, vol. 215(C).
    12. 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.
    13. Cheng, Guoqing & Li, Ling, 2020. "Joint optimization of production, quality control and maintenance for serial-parallel multistage production systems," Reliability Engineering and System Safety, Elsevier, vol. 204(C).

    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. de Jonge, Bram & Scarf, Philip A., 2020. "A review on maintenance optimization," European Journal of Operational Research, Elsevier, vol. 285(3), pages 805-824.
    2. Azimpoor, Samareh & Taghipour, Sharareh, 2021. "Joint inspection and product quality optimization for a system with delayed failure," Reliability Engineering and System Safety, Elsevier, vol. 215(C).
    3. Cheng, Guoqing & Li, Ling, 2020. "Joint optimization of production, quality control and maintenance for serial-parallel multistage production systems," Reliability Engineering and System Safety, Elsevier, vol. 204(C).
    4. Tambe, Pravin P. & Kulkarni, Makarand S., 2022. "A reliability based integrated model of maintenance planning with quality control and production decision for improving operational performance," Reliability Engineering and System Safety, Elsevier, vol. 226(C).
    5. 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.
    6. Cheng, Guo Qing & Zhou, Bing Hai & Li, Ling, 2018. "Integrated production, quality control and condition-based maintenance for imperfect production systems," Reliability Engineering and System Safety, Elsevier, vol. 175(C), pages 251-264.
    7. Ait-El-Cadi, Abdessamad & Gharbi, Ali & Dhouib, Karem & Artiba, Abdelhakim, 2021. "Integrated production, maintenance and quality control policy for unreliable manufacturing systems under dynamic inspection," International Journal of Production Economics, Elsevier, vol. 236(C).
    8. Sinisterra, Wilfrido Quiñones & Lima, Victor Hugo Resende & Cavalcante, Cristiano Alexandre Virginio & Aribisala, Adetoye Ayokunle, 2023. "A delay-time model to integrate the sequence of resumable jobs, inspection policy, and quality for a single-component system," Reliability Engineering and System Safety, Elsevier, vol. 230(C).
    9. Han, Xiao & Wang, Zili & Xie, Min & He, Yihai & Li, Yao & Wang, Wenzhuo, 2021. "Remaining useful life prediction and predictive maintenance strategies for multi-state manufacturing systems considering functional dependence," Reliability Engineering and System Safety, Elsevier, vol. 210(C).
    10. Lin Wang & Zhiqiang Lu & Yifei Ren, 2019. "A rolling horizon approach for production planning and condition-based maintenance under uncertain demand," Journal of Risk and Reliability, , vol. 233(6), pages 1014-1028, December.
    11. Alaswad, Suzan & Xiang, Yisha, 2017. "A review on condition-based maintenance optimization models for stochastically deteriorating system," Reliability Engineering and System Safety, Elsevier, vol. 157(C), pages 54-63.
    12. Wang, Yu & Xia, Tangbin & Xu, Yuhui & Si, Guojin & Wang, Dong & Pan, Ershun & Xi, Lifeng, 2024. "Quality-centered production and maintenance scheduling for multi-machine manufacturing systems under variable operating conditions," Reliability Engineering and System Safety, Elsevier, vol. 250(C).
    13. Boumallessa, Zeineb & Chouikhi, Houssam & Elleuch, Mounir & Bentaher, Hatem, 2023. "Modeling and optimizing the maintenance schedule using dynamic quality and machine condition monitors in an unreliable single production system," Reliability Engineering and System Safety, Elsevier, vol. 235(C).
    14. Xu, Jun & Liang, Zhenglin & Li, Yan-Fu & Wang, Kaibo, 2021. "Generalized condition-based maintenance optimization for multi-component systems considering stochastic dependency and imperfect maintenance," Reliability Engineering and System Safety, Elsevier, vol. 211(C).
    15. Wei, Shuaichong & Nourelfath, Mustapha & Nahas, Nabil, 2023. "Analysis of a production line subject to degradation and preventive maintenance," Reliability Engineering and System Safety, Elsevier, vol. 230(C).
    16. Li, Heping & Deloux, Estelle & Dieulle, Laurence, 2016. "A condition-based maintenance policy for multi-component systems with Lévy copulas dependence," Reliability Engineering and System Safety, Elsevier, vol. 149(C), pages 44-55.
    17. Barlow, E. & Bedford, T. & Revie, M. & Tan, J. & Walls, L., 2021. "A performance-centred approach to optimising maintenance of complex systems," European Journal of Operational Research, Elsevier, vol. 292(2), pages 579-595.
    18. 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).
    19. Rajesh Saha & Abdullahil Azeem & Kazi Wahadul Hasan & Syed Mithun Ali & Sanjoy Kumar Paul, 2021. "Integrated economic design of quality control and maintenance management: Implications for managing manufacturing process," 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. 12(2), pages 263-280, April.
    20. 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.

    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:reensy:v:199:y:2020:i:c:s0951832019309251. 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: https://www.journals.elsevier.com/reliability-engineering-and-system-safety .

    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.