IDEAS home Printed from https://ideas.repec.org/a/eee/reensy/v253y2025ics0951832024005702.html
   My bibliography  Save this article

Integrated optimization for X-bar control chart, preventive maintenance and production rate

Author

Listed:
  • Li, Yaping
  • Chen, Zhen
  • Xia, Tangbin
  • Pan, Ershun
  • Liu, Sifeng

Abstract

There are close relationships among statistical process control, maintenance, and production that have not fully explored in existing studies. In this study, we propose an economic model for jointly optimizing the X-bar control chart, preventive maintenance, and production rate. Unlike conventional studies relying on known failure rate functions, we employ a Gamma process to describe the system's deterioration. This approach allows us to consider not only the relationship between the production rate and the deterioration rate but also a broad range of deterioration scenarios and failure modes in the integrated optimization. After calculating the failure probability at each time point, we propose a recursive method to derive the production revenue, process control costs, and quality losses. This approach explores the close inner relationship between the production rate, deterioration, process monitoring and maintenance. Subsequently, we establish an optimization model aimed at maximizing the profit rate within a renewal cycle. The decision variables of this model include the production rate, control chart coefficient, sample size, length of the first sampling interval, and number of sampling intervals. Finally, we use a case study to illustrate the effectiveness and validity of our proposed model by identifying and explaining the interactions between production rate, deterioration, process control and maintenance.

Suggested Citation

  • Li, Yaping & Chen, Zhen & Xia, Tangbin & Pan, Ershun & Liu, Sifeng, 2025. "Integrated optimization for X-bar control chart, preventive maintenance and production rate," Reliability Engineering and System Safety, Elsevier, vol. 253(C).
  • Handle: RePEc:eee:reensy:v:253:y:2025:i:c:s0951832024005702
    DOI: 10.1016/j.ress.2024.110498
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0951832024005702
    Download Restriction: Full text for ScienceDirect subscribers only

    File URL: https://libkey.io/10.1016/j.ress.2024.110498?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. Naderkhani, Farnoosh & Makis, Viliam, 2016. "Economic design of multivariate Bayesian control chart with two sampling intervals," International Journal of Production Economics, Elsevier, vol. 174(C), pages 29-42.
    2. Yang, S.F. & Rahim, M.A., 2005. "Economic statistical process control for multivariate quality characteristics under Weibull shock model," International Journal of Production Economics, Elsevier, vol. 98(2), pages 215-226, November.
    3. Syan, Chanan S. & Ramsoobag, Geeta, 2019. "Maintenance applications of multi-criteria optimization: A review," Reliability Engineering and System Safety, Elsevier, vol. 190(C), pages 1-1.
    4. Yaping Li & Enrico Zio & Ershun Pan, 2021. "An MEWMA-based segmental multivariate hidden Markov model for degradation assessment and prediction," Journal of Risk and Reliability, , vol. 235(5), pages 831-844, October.
    5. Peng, Rui & Liu, Bin & Zhai, Qingqing & Wang, Wenbin, 2019. "Optimal maintenance strategy for systems with two failure modes," Reliability Engineering and System Safety, Elsevier, vol. 188(C), pages 624-632.
    6. He, Rui & Tian, Zhigang & Wang, Yifei & Zuo, Mingjian & Guo, Ziwei, 2023. "Condition-based maintenance optimization for multi-component systems considering prognostic information and degraded working efficiency," Reliability Engineering and System Safety, Elsevier, vol. 234(C).
    7. Li, Yaping & Xia, Tangbin & Chen, Zhen & Pan, Ershun, 2023. "Multiple degradation-driven preventive maintenance policy for serial-parallel multi-station manufacturing systems," Reliability Engineering and System Safety, Elsevier, vol. 230(C).
    8. Panagiotidou, Sofia & Tagaras, George, 2007. "Optimal preventive maintenance for equipment with two quality states and general failure time distributions," European Journal of Operational Research, Elsevier, vol. 180(1), pages 329-353, July.
    9. Polotski, V. & Kenne, J.-P. & Gharbi, A., 2019. "Joint production and maintenance optimization in flexible hybrid Manufacturing–Remanufacturing systems under age-dependent deterioration," International Journal of Production Economics, Elsevier, vol. 216(C), pages 239-254.
    10. Rasay, Hasan & Taghipour, Sharareh & Sharifi, Mani, 2022. "An integrated Maintenance and Statistical Process Control Model for a Deteriorating Production Process," Reliability Engineering and System Safety, Elsevier, vol. 228(C).
    11. de Jonge, Bram & Dijkstra, Arjan S. & Romeijnders, Ward, 2015. "Cost benefits of postponing time-based maintenance under lifetime distribution uncertainty," Reliability Engineering and System Safety, Elsevier, vol. 140(C), pages 15-21.
    12. Giovanni Celano & Subhabrata Chakraborti, 2021. "A distribution-free Shewhart-type Mann–Whitney control chart for monitoring finite horizon productions," International Journal of Production Research, Taylor & Francis Journals, vol. 59(20), pages 6069-6086, October.
    13. Xiaolin Wang & Lishuai Li & Min Xie, 2019. "Optimal preventive maintenance strategy for leased equipment under successive usage-based contracts," International Journal of Production Research, Taylor & Francis Journals, vol. 57(18), pages 5705-5724, September.
    14. Chen, Yiming & Liu, Yu & Jiang, Tao, 2021. "Optimal maintenance strategy for multi-state systems with single maintenance capacity and arbitrarily distributed maintenance time," Reliability Engineering and System Safety, Elsevier, vol. 211(C).
    15. Chen, Zhen & Li, Yaping & Xia, Tangbin & Pan, Ershun, 2019. "Hidden Markov model with auto-correlated observations for remaining useful life prediction and optimal maintenance policy," Reliability Engineering and System Safety, Elsevier, vol. 184(C), pages 123-136.
    16. George Nenes & Philippe Castagliola & Giovanni Celano, 2017. "Economic and statistical design of Vp control charts for finite-horizon processes," IISE Transactions, Taylor & Francis Journals, vol. 49(1), pages 110-125, January.
    17. Franco, Bruno Chaves & Celano, Giovanni & Castagliola, Philippe & Costa, Antonio Fernando Branco, 2014. "Economic design of Shewhart control charts for monitoring autocorrelated data with skip sampling strategies," International Journal of Production Economics, Elsevier, vol. 151(C), pages 121-130.
    18. Cha, Guesik & Park, Junseok & Moon, Ilkyeong, 2023. "Military aircraft flight and maintenance planning model considering heterogeneous maintenance tasks," Reliability Engineering and System Safety, Elsevier, vol. 239(C).
    19. 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).
    20. 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).
    21. Farnoosh Naderkhani, 2022. "Time to signal distribution of multivariate bayesian control chart with dual sampling scheme," International Journal of Production Research, Taylor & Francis Journals, vol. 60(20), pages 6124-6147, October.
    22. Qiuzhuang Sun & Piao Chen & Xin Wang & Zhi‐Sheng Ye, 2023. "Robust condition‐based production and maintenance planning for degradation management," Production and Operations Management, Production and Operations Management Society, vol. 32(12), pages 3951-3967, December.
    23. Guo Qing Cheng & Bing Hai Zhou & Ling Li, 2016. "Joint optimisation of production rate and preventive maintenance in machining systems," International Journal of Production Research, Taylor & Francis Journals, vol. 54(21), pages 6378-6394, November.
    24. Ben-Daya, M. & Rahim, M. A., 2000. "Effect of maintenance on the economic design of -control chart," European Journal of Operational Research, Elsevier, vol. 120(1), pages 131-143, January.
    25. Hasan Rasay & Mohammad Saber Fallahnezhad & Yahia Zaremehrjerdi, 2019. "An integrated model of statistical process control and maintenance planning for a two-stage dependent process under general deterioration," European Journal of Industrial Engineering, Inderscience Enterprises Ltd, vol. 13(2), pages 149-177.
    26. 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.
    27. Yousefi, Nooshin & Coit, David W. & Song, Sanling & Feng, Qianmei, 2019. "Optimization of on-condition thresholds for a system of degrading components with competing dependent failure processes," Reliability Engineering and System Safety, Elsevier, vol. 192(C).
    28. Pinciroli, Luca & Baraldi, Piero & Zio, Enrico, 2023. "Maintenance optimization in industry 4.0," Reliability Engineering and System Safety, Elsevier, vol. 234(C).
    Full references (including those not matched with items on IDEAS)

    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. 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).
    2. 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).
    3. 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).
    4. 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).
    5. Yin, Hui & Zhang, Guojun & Zhu, Haiping & Deng, Yuhao & He, Fei, 2015. "An integrated model of statistical process control and maintenance based on the delayed monitoring," Reliability Engineering and System Safety, Elsevier, vol. 133(C), pages 323-333.
    6. Xiang, Yisha, 2013. "Joint optimization of X¯ control chart and preventive maintenance policies: A discrete-time Markov chain approach," European Journal of Operational Research, Elsevier, vol. 229(2), pages 382-390.
    7. Perdikis, Theodoros & Celano, Giovanni & Chakraborti, Subhabrata, 2024. "Distribution-free control charts for monitoring scale in finite horizon productions," European Journal of Operational Research, Elsevier, vol. 314(3), pages 1040-1051.
    8. Pan Zheng & Wenqin Zhao & Yaqiong Lv & Lu Qian & Yifan Li, 2022. "Health Status-Based Predictive Maintenance Decision-Making via LSTM and Markov Decision Process," Mathematics, MDPI, vol. 11(1), pages 1-13, December.
    9. 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).
    10. Xiao, Xiao & Jiang, Wei & Luo, Jianwen, 2019. "Combining process and product information for quality improvement," International Journal of Production Economics, Elsevier, vol. 207(C), pages 130-143.
    11. 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).
    12. An, Youjun & Chen, Xiaohui & Hu, Jiawen & Zhang, Lin & Li, Yinghe & Jiang, Junwei, 2022. "Joint optimization of preventive maintenance and production rescheduling with new machine insertion and processing speed selection," Reliability Engineering and System Safety, Elsevier, vol. 220(C).
    13. Tomohiro, Ryosuke & Arizono, Ikuo & Takemoto, Yasuhiko, 2020. "Economic design of double sampling Cpm control chart for monitoring process capability," International Journal of Production Economics, Elsevier, vol. 221(C).
    14. Panagiotidou, Sofia & Nenes, George, 2009. "An economically designed, integrated quality and maintenance model using an adaptive Shewhart chart," Reliability Engineering and System Safety, Elsevier, vol. 94(3), pages 732-741.
    15. Zhao, Xian & Li, Rong & Han, He & Qiu, Qingan, 2025. "Condition-based switching, loading, and age-based maintenance policies for standby systems," European Journal of Operational Research, Elsevier, vol. 321(2), pages 565-585.
    16. 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).
    17. Leoni, Leonardo & De Carlo, Filippo & Tucci, Mario, 2023. "Developing a framework for generating production-dependent failure rate through discrete-event simulation," International Journal of Production Economics, Elsevier, vol. 266(C).
    18. 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.
    19. 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).
    20. Cavalcante, Cristiano A.V. & Lopes, Rodrigo S. & Scarf, Philip A., 2021. "Inspection and replacement policy with a fixed periodic schedule," Reliability Engineering and System Safety, Elsevier, vol. 208(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:253:y:2025:i:c:s0951832024005702. 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.