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A cost minimisation model for joint production and maintenance planning under quality constraints

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  • Hossein Beheshti Fakher
  • Mustapha Nourelfath
  • Michel Gendreau

Abstract

In this paper, integrated planning of production, imperfect maintenance and process inspections in a multi-machine system is investigated. This system consists of parallel machines which deteriorate with time and they may shift from a primarily in-control state to a degraded state with a higher defective rate or to a failed state. Maintenance scheduling corresponds to a discrete time age-based imperfect maintenance with a large number of maintenance alternatives. Process inspections are considered to detect the current state of the system. Detecting a deteriorated condition initiates the quality check of the related sub-lots, rework of defective items and a process adjustment that brings the machine in its normal conditions. Production planning includes a capacitated lot-sizing problem with multiple products. We propose a joint approach that coordinates the decisions of the three functions, where the objective function minimises the total cost. Evaluation of costs and interacting factors is presented and two heuristic methods are proposed to solve the problem. The results of the joint model are compared to a non-integrated method and a sensitivity analysis is conducted.

Suggested Citation

  • Hossein Beheshti Fakher & Mustapha Nourelfath & Michel Gendreau, 2017. "A cost minimisation model for joint production and maintenance planning under quality constraints," International Journal of Production Research, Taylor & Francis Journals, vol. 55(8), pages 2163-2176, April.
    • Handle: RePEc:taf:tprsxx:v:55:y:2017:i:8:p:2163-2176
    DOI: 10.1080/00207543.2016.1201605
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    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. Xia, Tangbin & Dong, Yifan & Xiao, Lei & Du, Shichang & Pan, Ershun & Xi, Lifeng, 2018. "Recent advances in prognostics and health management for advanced manufacturing paradigms," Reliability Engineering and System Safety, Elsevier, vol. 178(C), pages 255-268.
    3. 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).
    4. Kafiabad, Shayan Tavakoli & Kazemi Zanjani, Masoumeh & Nourelfath, Mustapha, 2020. "Integrated planning of operations and on-job training in maintenance logistics networks," Reliability Engineering and System Safety, Elsevier, vol. 199(C).
    5. 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).

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