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Joint optimisation of production, maintenance and quality for batch production system subject to varying operational conditions

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  • Lin Wang
  • Zhiqiang Lu
  • Xiaole Han

Abstract

This paper considers the integration problem of production, maintenance and quality for a capacitated lot-sizing production system subject to deterioration. The effects of varying operational conditions from batch to batch on system reliability and product quality are modelled by proportional hazards models, resulting in non-monotonic failure rate and defect rate. After each batch production, imperfect preventive maintenance (PM) is determined to mitigate the system deterioration, and inspection is taken to sort nonconforming items in the finished goods. Once the cumulative number of nonconforming items exceeds a predetermined threshold, an overhaul is performed to renew the system. An integrated model for optimising production plan, PM plan and overhaul strategy is developed to minimise the total cost while satisfying all product demands. A genetic algorithm is proposed to solve the integrated model efficiently. Numerical results validate the rationality of the model with varying operational conditions consideration and its applicability in economic benefits.

Suggested Citation

  • Lin Wang & Zhiqiang Lu & Xiaole Han, 2019. "Joint optimisation of production, maintenance and quality for batch production system subject to varying operational conditions," International Journal of Production Research, Taylor & Francis Journals, vol. 57(24), pages 7552-7566, December.
    • Handle: RePEc:taf:tprsxx:v:57:y:2019:i:24:p:7552-7566
    DOI: 10.1080/00207543.2019.1581956
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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. Xiao, Lei & Zhang, Xinghui & Tang, Junxuan & Zhou, Yaqin, 2020. "Joint optimization of opportunistic maintenance and production scheduling considering batch production mode and varying operational conditions," Reliability Engineering and System Safety, Elsevier, vol. 202(C).
    3. 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).
    4. 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).
    5. Absi, Nabil & van den Heuvel, Wilco & Dauzère-Pérès, Stéphane, 2024. "Complexity analysis of integrated dynamic lot sizing and maintenance planning problems," European Journal of Operational Research, Elsevier, vol. 318(1), pages 100-109.
    6. 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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