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Joint optimization of production, quality control and maintenance for serial-parallel multistage production systems

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  • Cheng, Guoqing
  • Li, Ling

Abstract

This paper presents a joint model of production, quality control and preventive maintenance for a serial-parallel multistage production system. In each stage, there are multiple machines to meet the productivity and line-balance requirement. The machines deteriorate with usage and thus influences the product quality. A make-to-stock production policy is adopted to provide protection to stock against uncertainties. All items processed in each stage undergo quality checks. Conforming items are delivered to the next stage for further processing, whereas non-conforming items are scrapped. During production runs, based on the quality information feedback, preventive maintenances are performed to improve the machines reliability and hence the product quality. At the end of production runs, machines are inspected and maintained if necessary. The novelty of the proposed maintenance strategy consists in that both the machine structure importance measure and productivity are considered when selecting machines for maintenance. It aims to simultaneously determine the length of production run, quality control-threshold and maintenance-threshold such that the average cost rate is minimized. A stochastic mathematical model is developed which is solved by a simulation-based optimization approach coupling Monte Carlo Simulation and genetic algorithm. Finally, an illustrative example and some comparisons are provided to demonstrate the model.

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  • 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).
    • Handle: RePEc:eee:reensy:v:204:y:2020:i:c:s0951832020306475
    DOI: 10.1016/j.ress.2020.107146
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    2. Grzegorz Kłosowski & Monika Kulisz & Jerzy Lipski & Michal Maj & Ryszard Bialek, 2021. "The Use of Transfer Learning with Very Deep Convolutional Neural Network in Quality Management," European Research Studies Journal, European Research Studies Journal, vol. 0(Special 2), pages 253-263.
    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).
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    5. 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).
    6. 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.
    7. 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).
    8. 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.
    9. Kim, Seokgoo & Choi, Joo-Ho & Kim, Nam Ho, 2022. "Inspection schedule for prognostics with uncertainty management," Reliability Engineering and System Safety, Elsevier, vol. 222(C).
    10. 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).
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    12. Aminu Sahabi Abubakar & Zied Hajej & Aime C. Nyoungue, 2023. "Multi-Product Production Optimization of Maintenance Integrated into the Control Chart Under Service Level and Quality Constraints," International Journal of Operations Management, Inovatus Services Ltd., vol. 3(2), pages 7-21, May.

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