IDEAS home Printed from https://ideas.repec.org/a/eee/reensy/v226y2022ics0951832022002459.html
   My bibliography  Save this article

Joint optimization of production and maintenance for a serial–parallel hybrid two-stage production system

Author

Listed:
  • Shen, Yilan
  • Zhang, Xi
  • Shi, Leyuan

Abstract

Effective machine maintenance and job scheduling strategies are two critical interactive tasks to upgrade the production efficiency in manufacturing industries. In this study, we mainly consider the interaction between production scheduling and maintenance, while optimizing the job scheduling problem in a serial–parallel hybrid two-stage production system. We formulate the problem by introducing the stochastic and workload-ratio degradation, and the actual job completion time and maintenance costs can be modeled according to the degradation status of each machine. To solve this problem, a two-step opportunistic maintenance (OM) strategy is developed, and finally an adaptive random-key genetic algorithm (GA) is designed by incorporating the OM coefficients. Numerical studies have been conducted to validate the proposed approach, and the results indicate the effectiveness compared to three existing methods under varying machine degradation scenarios.

Suggested Citation

  • 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).
    • Handle: RePEc:eee:reensy:v:226:y:2022:i:c:s0951832022002459
    DOI: 10.1016/j.ress.2022.108600
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0951832022002459
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.ress.2022.108600?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. Song, Sanling & Coit, David W. & Feng, Qianmei, 2014. "Reliability for systems of degrading components with distinct component shock sets," Reliability Engineering and System Safety, Elsevier, vol. 132(C), pages 115-124.
    2. 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.
    3. Ye, Zhenggeng & Cai, Zhiqiang & Zhou, Fuli & Zhao, Jiangbin & Zhang, Pan, 2019. "Reliability analysis for series manufacturing system with imperfect inspection considering the interaction between quality and degradation," Reliability Engineering and System Safety, Elsevier, vol. 189(C), pages 345-356.
    4. Shi, Yue & Zhu, Weihang & Xiang, Yisha & Feng, Qianmei, 2020. "Condition-based maintenance optimization for multi-component systems subject to a system reliability requirement," Reliability Engineering and System Safety, Elsevier, vol. 202(C).
    5. Qiuzhuang Sun & Zhi-Sheng Ye & Xiaoyan Zhu, 2020. "Managing component degradation in series systems for balancing degradation through reallocation and maintenance," IISE Transactions, Taylor & Francis Journals, vol. 52(7), pages 797-810, July.
    6. Zhou, Xiaojun & Shi, Kailong, 2019. "Capacity failure rate based opportunistic maintenance modeling for series-parallel multi-station manufacturing systems," Reliability Engineering and System Safety, Elsevier, vol. 181(C), pages 46-53.
    7. Delorme, Maxence & Iori, Manuel & Mendes, Nilson F.M., 2021. "Solution methods for scheduling problems with sequence-dependent deterioration and maintenance events," European Journal of Operational Research, Elsevier, vol. 295(3), pages 823-837.
    8. S. P. Sethi & H. Yan & H. Zhang & Q. Zhang, 2002. "Optimal and Hierarchical Controls in Dynamic Stochastic Manufacturing Systems: A Survey," Manufacturing & Service Operations Management, INFORMS, vol. 4(2), pages 133-170.
    9. van Noortwijk, J.M., 2009. "A survey of the application of gamma processes in maintenance," Reliability Engineering and System Safety, Elsevier, vol. 94(1), pages 2-21.
    10. Lahcen Mifdal & Zied Hajej & Sofiene Dellagi, 2015. "Joint Optimization Approach of Maintenance and Production Planning for a Multiple-Product Manufacturing System," Mathematical Problems in Engineering, Hindawi, vol. 2015, pages 1-17, April.
    11. 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).
    12. Laith A. Hadidi & Umar M. Al-Turki & Abdur Rahim, 2012. "Integrated models in production planning and scheduling, maintenance and quality: a review," International Journal of Industrial and Systems Engineering, Inderscience Enterprises Ltd, vol. 10(1), pages 21-50.
    13. Ma, Xiaoyang & Liu, Bin & Yang, Li & Peng, Rui & Zhang, Xiaodong, 2020. "Reliability analysis and condition-based maintenance optimization for a warm standby cooling system," Reliability Engineering and System Safety, Elsevier, vol. 193(C).
    14. 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).
    15. Cheng, T.C.E. & Yang, Suh-Jenq & Yang, Dar-Li, 2012. "Common due-window assignment and scheduling of linear time-dependent deteriorating jobs and a deteriorating maintenance activity," International Journal of Production Economics, Elsevier, vol. 135(1), pages 154-161.
    16. Young Myoung Ko & Eunshin Byon, 2017. "Condition-based joint maintenance optimization for a large-scale system with homogeneous units," IISE Transactions, Taylor & Francis Journals, vol. 49(5), pages 493-504, May.
    17. Leung, Kit-Nam Francis, 2007. "A generalized geometric-programming solution to "An economic production quantity model with flexibility and reliability considerations"," European Journal of Operational Research, Elsevier, vol. 176(1), pages 240-251, January.
    18. 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).
    19. Gharbi, Anis & Ladhari, Talel & Msakni, Mohamed Kais & Serairi, Mehdi, 2013. "The two-machine flowshop scheduling problem with sequence-independent setup times: New lower bounding strategies," European Journal of Operational Research, Elsevier, vol. 231(1), pages 69-78.
    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. Chen, Zhaoxiang & Chen, Zhen & Zhou, Di & Pan, Ershun, 2023. "Energy-oriented opportunistic maintenance optimization of continuous process manufacturing systems with two types of stochastic durations," Reliability Engineering and System Safety, Elsevier, vol. 237(C).
    2. Zhang, Nan & Cai, Kaiquan & Deng, Yingjun & Zhang, Jun, 2024. "Joint optimization of condition-based maintenance and condition-based production of a single equipment considering random yield and maintenance delay," Reliability Engineering and System Safety, Elsevier, vol. 241(C).
    3. Jun Wang & Yuyang Wang & Yuqiang Fu, 2023. "Joint Optimization of Condition-Based Maintenance and Performance Control for Linear Multi-State Consecutively Connected Systems," Mathematics, MDPI, vol. 11(12), pages 1-19, June.
    4. Alotaibi, Naif M. & Scarf, Philip & Cavalcante, Cristiano A.V. & Lopes, Rodrigo S. & de Oliveira e Silva, André Luiz & Rodrigues, Augusto J.S. & Alyami, Salem A., 2023. "Modified-opportunistic inspection and the case of remote, groundwater well-heads," Reliability Engineering and System Safety, Elsevier, vol. 237(C).
    5. Jiang, Weixin & Cui, Lirong & Liang, Xiaojun, 2024. "Optimal maintenance policies for three-unit parallel production systems considering yields," Reliability Engineering and System Safety, Elsevier, vol. 248(C).
    6. Pinciroli, Luca & Baraldi, Piero & Zio, Enrico, 2023. "Maintenance optimization in industry 4.0," Reliability Engineering and System Safety, Elsevier, vol. 234(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. 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).
    2. 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).
    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. Uit Het Broek, Michiel A.J. & Teunter, Ruud H. & de Jonge, Bram & Veldman, Jasper, 2021. "Joint condition-based maintenance and load-sharing optimization for two-unit systems with economic dependency," European Journal of Operational Research, Elsevier, vol. 295(3), pages 1119-1131.
    5. Chen, Yuan & Qiu, Qingan & Zhao, Xian, 2022. "Condition-based opportunistic maintenance policies with two-phase inspections for continuous-state systems," Reliability Engineering and System Safety, Elsevier, vol. 228(C).
    6. Jun Wang & Yuyang Wang & Yuqiang Fu, 2023. "Joint Optimization of Condition-Based Maintenance and Performance Control for Linear Multi-State Consecutively Connected Systems," Mathematics, MDPI, vol. 11(12), pages 1-19, June.
    7. Zhao, Xian & He, Zongda & Wu, Yaguang & Qiu, Qingan, 2022. "Joint optimization of condition-based performance control and maintenance policies for mission-critical systems," Reliability Engineering and System Safety, Elsevier, vol. 226(C).
    8. 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).
    9. Kampitsis, Dimitris & Panagiotidou, Sofia, 2022. "A Bayesian condition-based maintenance and monitoring policy with variable sampling intervals," Reliability Engineering and System Safety, Elsevier, vol. 218(PA).
    10. 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).
    11. Najafi, Seyedvahid & Zheng, Rui & Lee, Chi-Guhn, 2021. "An optimal opportunistic maintenance policy for a two-unit series system with general repair using proportional hazards models," Reliability Engineering and System Safety, Elsevier, vol. 215(C).
    12. Yousefi, Nooshin & Coit, David W. & Song, Sanling, 2020. "Reliability analysis of systems considering clusters of dependent degrading components," Reliability Engineering and System Safety, Elsevier, vol. 202(C).
    13. 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).
    14. 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.
    15. Zhang, Jian-Xun & Du, Dang-Bo & Si, Xiao-Sheng & Hu, Chang-Hua & Zhang, Han-Wen, 2021. "Joint optimization of preventive maintenance and inventory management for standby systems with hybrid-deteriorating spare parts," Reliability Engineering and System Safety, Elsevier, vol. 214(C).
    16. Michiel A. J. uit het Broek & Ruud H. Teunter & Bram de Jonge & Jasper Veldman & Nicky D. Van Foreest, 2020. "Condition-Based Production Planning: Adjusting Production Rates to Balance Output and Failure Risk," Manufacturing & Service Operations Management, INFORMS, vol. 22(4), pages 792-811, July.
    17. Truong-Ba, Huy & Cholette, Michael E. & Rebello, Sinda & Kent, Geoff, 2024. "Joint planning of inspection, replacement, and component decommissioning for a series system with non-identically degrading components," Reliability Engineering and System Safety, Elsevier, vol. 241(C).
    18. Zhang, Nan & Fouladirad, Mitra & Barros, Anne & Zhang, Jun, 2020. "Condition-based maintenance for a K-out-of-N deteriorating system under periodic inspection with failure dependence," European Journal of Operational Research, Elsevier, vol. 287(1), pages 159-167.
    19. de Jonge, Bram & Scarf, Philip A., 2020. "A review on maintenance optimization," European Journal of Operational Research, Elsevier, vol. 285(3), pages 805-824.
    20. Zhou, Yifan & Li, Bangcheng & Lin, Tian Ran, 2022. "Maintenance optimisation of multicomponent systems using hierarchical coordinated reinforcement learning," Reliability Engineering and System Safety, Elsevier, vol. 217(C).

    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:226:y:2022:i:c:s0951832022002459. 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.