Optimal maintenance of two stochastically deteriorating machines with an intermediate buffer

We consider a manufacturing system in which an input generating installation transfers a raw material to a subsequent production unit. Both machines deteriorate stochastically with usage and may fail. For each machine the deteriorating process is described by some known transition probabilities between different degrees of deterioration. A buffer has been built between the two machines in order to cope with unexpected failures of the installation. A discrete-time Markov decision model is formulated for the optimal preventive maintenance of both machines. The maintenance times are geometrically distributed and the cost structure includes operating costs, storage costs, maintenance costs and costs due to the lost production. It is proved that for fixed buffer content and for fixed deterioration degree of one machine, the average-cost optimal policy initiates a preventive maintenance of the other machine if and only if its degree of deterioration exceeds some critical level. We study, by means of numerical results, the effect of the variation of some parameters on the optimal policy and on the minimum average cost. For the case in which the maintenance times follow continuous distributions, an approximate discrete-time Markov decision model is proposed.     

Contribution of simulation to the optimization of maintenance strategies for a randomly failing production system

This paper compares two strategies for operating a production system composed of two machines working in parallel and a downstream inventory supplying an assembly line. The two machines, which are prone to random failures, undergo preventive and corrective maintenance operations. These operations with a random duration make the machines unavailable. Moreover, during regular subcontracting operations, one of these machines becomes unavailable to supply the downstream inventory. In the first strategy it is assumed that the periodicity of preventive maintenance operations and the production rate of each machine are independent. The second strategy suggests an interaction between the periods of unavailability and the production rates of the two machines in order to minimize production losses during these periods. A simulation model for each strategy is developed so as to be able to compare them and to simultaneously determine the timing of preventive maintenance on each machine considering the total average cost per time unit as the performance criterion. The second strategy is then considered, and a multi-criteria analysis is adopted to reach the best cost-availability compromise.     

Unrelated parallel-machine scheduling with deterioration effects and deteriorating multi-maintenance activities for minimizing the total completion time

This paper investigates scheduling problems with simultaneous considerations of deterioration effects and deteriorating multi-maintenance activities on unrelated parallel machines. We examine two models of scheduling with the deterioration effect, namely the job-dependent and position-dependent deterioration model and the time-dependent deterioration model. We assume that each machine may be subject to several maintenance activities over the scheduling horizon, and the duration of maintenance on a machine depends on its running time. Moreover, due to the restriction of the budget of maintenance, the upper bound of the total maintenance frequencies on all the machines is assumed to be known in advance. The objective is to find jointly the optimal maintenance frequencies, the optimal maintenance positions, and the optimal job sequences such that the total completion time is minimized. If the number of machines is fixed, we introduce polynomial time solutions for all the versions of the problem under study.     

Parallel machines scheduling to minimize job tardiness and machine deteriorating cost with deteriorating jobs

This paper studies the parallel machines bi-criteria scheduling problem (PMBSP) in a deteriorating system. Sequencing and scheduling problems (SSP) have seldom considered the two phenomena concurrently. This paper discusses the parallel machines scheduling problem with the effects of machine and job deterioration. By the machine deterioration effect, we mean that each machine deteriorates at a different rate. This deterioration is considered in terms of cost which depends on the production rate, the machine’s operating characteristics and the kind of work done by each machine. Moreover, job processing times are increasing functions of their starting times and follow a simple linear deterioration. The objective functions are minimizing total tardiness and machine deteriorating cost. The problem of total tardiness on identical parallel machines is NP-hard, thus the problem with machine deteriorating cost as an additional term is also NP-hard. We propose the LP-metric method to show the importance of our proposed multi-objective problem. A metaheuristic algorithm is developed to locate optimal or near optimal solutions based on a Tabu search mechanism. Numerical examples are presented to show the efficiency of this model.     

A Two-Level Production Control Model with Target Amount Rescheduling

This paper deals with the problem of two-level production control with disturbances. A production system is considered with several machines on the lower level and a section on the upper one. Each machine produces a given target amount by a given due date (common to all machines). Each machine has several possible speeds, which are subject to disturbances. On the machine level, at the routine control point, decision-making centres on introducing the proper speed and determining the next control point. It is assumed that all the target amounts are transferable; i.e. a part of each target amount can be processed by any other machine. In a case when it is realized, for a certain machine, that the target cannot be completed on time, the section reschedules the remaining target amounts among the machines. New target amounts are determined for the machines so that the overall target can be accomplished on time. A stochastic optimization formulation is presented, followed by a heuristic solution and simulation results.     

A Genetic Algorithm for the Allocation of Buffer Storage Capacities in a Production Line with Unreliable Machines

In this paper, we consider a flow-line manufacturing system organized as a series of workstations separated by finite buffers. The failure and repair times of machines are supposed to be exponentially distributed. The production rate of each machine is deterministic, and different machines may have different production rates. The buffer allocation problem consists in determining the buffer capacities with respect to a given optimality criterion, which depends on the average production rate of the line, the buffer acquisition and installation cost, and the inventory cost. For this problem we propose a genetic algorithm where the tentative solutions are evaluated with an approximate method based on the Markov-model aggregation approach.     

Cost analysis of the M/M/R machine repair problem with balking,reneging, and server breakdowns

We consider the machine repair problem in which failed machines balk (do not enter) with a constant probability (1 – b) and renege (leave the queue after entering) according to a negative exponential distribution. A group of identical automatic machines are maintained by R servers which themselves are subject to breakdowns. Failure and service times of the machines, and breakdown and repair times of the servers, are assumed to follow a negative exponential distribution. Each server is subject to breakdown even if no failed machines are in the system. This paper presents a matrix geometric method for deriving the steady-state probabilities, using which various system performance measures that can be obtained. A cost model is developed to determine the optimum number of servers. The minimum expected cost, the optimal number of servers, and various system performance measures are provided based on assumed numerical values given to the system parameters. Also the sensitivity analysis is investigated.     

Monitoring machine operations using on-line sensors

Monitoring machine operations and production process conditions using on-line sensors has drawn increasing attention recently. In this paper, we discuss a situation where an on-line sensor is used to monitor a randomly deteriorating machine operation. The machine condition is described by a finite number of states, and the machine deterioration follows a Markov process. It is assumed that the sensor measurement and the true machine condition have a statistical relation. A decision is to be made on when a machine setup should be made, based on the observed sensor measurement. A Markovian model is developed by considering the cost of operating the machine and the cost of performing preventive maintenance, and a steady state threshold policy is developed by minimizing the total cost. In addition, a heuristic method based on Bayes rule is proposed. A simulation study is used to study and compare the properties of these two policies.     

Cost Analysis of the <Emphasis Type="Italic">M/M/R</Emphasis> Machine Repair Problem with Spares and Two Modes of Failure

In this paper we deal with the machine repair problem consisting of M operating machines with S spare machines, and R repairmen where machines have two failure modes under steady-state conditions. Spares are considered to be either cold-standby, warm-standby or hot-standby. The two failure modes have equal probability of repair. Failure time of the machines and repair time of the repairmen are assumed to follow a negative exponential distribution. A cost model is developed in order to determine the optimal values of the number of repairmen and the number of spares simultaneously, while maintaining a minimum specified level of system availability. Numerical results are presented in which several system characteristics are evaluated for three types of standby under optimal operating conditions.     

Multi-machine scheduling with deteriorating jobs and scheduled maintenance

In this paper, we investigate a multi-machine scheduling problem in which job processing times are increasing functions of their starting times and machines are not always available. Job processing times are assumed to follow simple linear deteriorations. Moreover, each machine is assumed to have a maintenance period which is known in advance. Both the resumable and non-resumable cases are discussed with the objective of minimizing the makespan. A lower bound and a heuristic algorithm are derived for each case. Numerical results are also provided to evaluate the efficiency of the proposed procedures.     

On a production-inventory system of deteriorating items subject to random machine breakdowns with a fixed repair time

This paper considers the impact of random machine breakdowns on the classical Economic Production Quantity (EPQ) model for a product subject to exponential decay and under a no-resumption (NR) inventory control policy. A product is manufactured in batches on a machine that is subject to random breakdowns in order to meet a constant demand over an infinite planning horizon. The product is assumed to have a significant rate of deterioration and time to deterioration is described by an exponential distribution. Also, the time-to-breakdown is a random variable following an exponential distribution. Under the NR policy, when a breakdown occurs during a production run, the run is immediately aborted. A new run will not be started until all available inventories are depleted. Corrective maintenance of the production system is carried out immediately after a breakdown and it takes a fixed period of time to complete such an activity. The objective is to determine the optimal production uptime that minimizes the expected total cost per unit time consisting of setup, corrective maintenance, inventory carrying, deterioration, and lost sales costs. A near optimal production uptime is derived under conditions of continuous review, deterministic demand, and no shortages.     

Intermediate buffer analysis for a production system

In this paper, a production system consisting of two serial machines and an intermediate buffer is studied. A shortage cost is incurred when the upstream machine is down and the buffer is exhausted. The practical example for this type of system can be an automated work center or an automobile general assembly.Researches on a similar two-machine system have been done in some articles where maintenance and an intermediate buffer are considered, but the spare parts are not involved. Nevertheless, spare parts are essential for maintenance implementation, and there is interaction between the buffer inventory and the spare parts due to maintenance activity. This paper is aimed to investigate three types of cost related to the intermediate buffer inventory, and obtain their expectations as functions of several decision parameters on maintenance, buffer, and spare parts during a renewal cycle, by using mathematical analysis. The proposed method can be an important basis for further study of system cost calculation and decision making optimization.     

Index policies for the maintenance of a collection of machines by a set of repairmen

A collection of M machines which deteriorate under usage is maintained by a set of R repairmen who may have other tasks to perform. Maintenance interventions will improve a machine's condition and may preempt costly breakdowns. The problem of scheduling such interventions to minimise the total expected discounted cost incurred in operating the machines over an infinite horizon is formulated as a Markov Decision Process which has the form of a restless bandit problem. We outline an approach to the development of maintenance policies based on simple machine indices in the form of a fair charge for a maintenance intervention in the machine's current state. Closed form indices are derived for two particular models. Numerical investigations demonstrate the strong performance of the derived index heuristics.     

A new MIP model for mine equipment scheduling by minimizing maintenance cost

Mining investment has been recognized as capital intensive due mainly to the cost of large equipment. Equipment capital costs for a given operation are usually within the order of hundreds of million dollars but may reach to billion dollars for large companies operating multiple mines. Such large investments require the optimum usage of equipment in a manner that the operating costs are minimized and the utilization of equipment is maximized through optimal scheduling. This optimum usage is required to ensure that the business remains sustainable and financially stable. Most mining operations utilize trucks to haul the mined material. Maintenance is one of the major operating cost items for these fleets as it can reach approximately one hundred million dollars yearly. There is no method or application in the literature that optimizes the utilization for truck fleet over the life of mine. A new approach based on mixed integer programming (MIP) techniques is used for annually scheduling a fixed fleet of mining trucks in a given operation, over a multi-year time horizon to minimize maintenance cost. The model uses the truck age (total hours of usage), maintenance cost and required operating hours to achieve annual production targets to produce an optimum truck schedule. While this paper focuses on scheduling trucks for mining operation, concept can be used in most businesses using equipment with significant maintenance costs. A case study for a large scale gold mine showed an annual discounted (10% rate) maintenance cost saving of over $2M and more than 16% ($21M) of overall maintenance cost reduction over 10 years of mine life, compared with the spreadsheet based approach used currently at the operation.     

The Decision to Repair or Scrap a Machine

A simple algebraic formula for combining repair data with prior experience determines the time when a machine should be replaced in order to minimize the expected cost of equipment purchase and maintenance. A random sample from an exponential distribution represents the cost of each repair, and a time-dependent Poisson process represents the intervals between repairs. Bayes' formula provides the basis for combining data with previous judgement about the characteristics of the equipment. Automobile maintenance records support the basic assumptions of the model, and illustrate the method of deciding when to scrap a given machine.     

Machine reliability and preventive maintenance planning for cellular manufacturing systems

The paper proposes a preventive maintenance (PM) planning model for the performance improvement of cellular manufacturing systems (CMS) in terms of machine reliability, and resource utilization. In a CMS, parts are processed by a group of interdependent machines, where machine reliability plays an important role in the performance improvement of the cell. Assuming that machine failure times follow a Weibull distribution, the proposed model determines a PM interval and a schedule for performing PM actions on each machine in the cell by minimizing the total maintenance cost and the overall probability of machine failures. The model uses a combined cost and reliability based approach, and optimizes maintenance costs by administering a group maintenance policy subject to a desirable machine reliability threshold. The study also proposes a CMS design model that integrates the above PM concepts into the design process. Illustrative examples are presented to demonstrate the applicability of the proposed approach.     

Online scheduling with general machine cost functions

For most scheduling problems the set of machines is fixed initially and remains unchanged for the duration of the problem. Recently online scheduling problems have been investigated with the modification that initially the algorithm possesses no machines, but that at any point additional machines may be purchased. In all of these models the assumption has been made that each machine has unit cost. In this paper we consider the problem with general machine cost functions. Furthermore we also consider a more general version of the problem where the available machines have speed, the algorithm may purchase machines with speed 1 and machines with speed s. We define and analyze some algorithms for the solution of these problems and their special cases. Moreover we prove some lower bounds on the possible competitive ratios.     

Linear feature-weighted support vector machine

The existing support vector machines (SVMs) are all assumed that all the features of training samples have equal contributions to construct the optimal separating hyperplane. However, for a certain real-world data set, some features of it may possess more relevances to the classification information, while others may have less relevances. In this paper, the linear feature-weighted support vector machine (LFWSVM) is proposed to deal with the problem. Two phases are employed to construct the proposed model. First, the mutual information (MI) based approach is used to assign appropriate weights for each feature of the whole given data set. Second, the proposed model is trained by the samples with their features weighted by the obtained feature weight vector. Meanwhile, the feature weights are embedded in the quadratic programming through detailed theoretical deduction to obtain the dual solution to the original optimization problem. Although the calculation of feature weights may add an extra computational cost, the proposed model generally exhibits better generalization performance over the traditional support vector machine (SVM) with linear kernel function. Experimental results upon one synthetic data set and several benchmark data sets confirm the benefits in using the proposed method. Moreover, it is also shown in experiments that the proposed MI based approach to determining feature weights is superior to the other two mostly used methods.     

Optimal management of the machine repair problem with working vacation: Newton’s method

This paper studies the M/M/1 machine repair problem with working vacation in which the server works with different repair rates rather than completely terminating the repair during a vacation period. We assume that the server begins the working vacation when the system is empty. The failure times, repair times, and vacation times are all assumed to be exponentially distributed. We use the MAPLE software to compute steady-state probabilities and several system performance measures. A cost model is derived to determine the optimal values of the number of operating machines and two different repair rates simultaneously, and maintain the system availability at a certain level. We use the direct search method and Newton’s method for unconstrained optimization to repeatedly find the global minimum value until the system availability constraint is satisfied. Some numerical examples are provided to illustrate Newton’s method.     

Hierarchical Production Control in Dynamic Stochastic Jobshops with Long-Run Average Cost

We consider a production planning problem for a dynamic jobshop producing a number of products and subject to breakdown and repair of machines. The machine capacities are assumed to be finite-state Markov chains. As the rates of change of the machine states approach infinity, an asymptotic analysis of this stochastic manufacturing systems is given. The analysis results in a limiting problem in which the stochastic machine availability is replaced by its equilibrium mean availability. The long-run average cost for the original problem is shown to converge to the long-run average cost of the limiting problem. The convergence rate of the long-run average cost for the original problem to that of the limiting problem together with an error estimate for the constructed asymptotic optimal control is established.