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

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  • 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
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    Cited by:

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    2. 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.
    3. 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).
    4. 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).
    5. 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).
    6. 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).
    7. 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).
    8. 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).
    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. 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).
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    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).

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