Age-dependent production planning and maintenance strategies in unreliable manufacturing systems with lost sale

In this paper, we formulate an analytical model for the joint determination of an optimal age-dependent buffer inventory and preventive maintenance policy in a production environment that is subject to random machine breakdowns. Traditional preventive maintenance policies, such as age and periodic replacements, are usually studied based on simplified and non-realistic assumptions, as well as on the expected costs criterion. Finished goods inventories and the age-dependent likelihood of machine breakdowns are usually not considered. As a result, these policies could significantly extend beyond the anticipated financial incomes of the system, and lead to crises. In order to solve this problem, a more realistic analysis model is proposed in this paper to consider the effects of both preventive maintenance policies and machine age on optimal safety stock levels. Hence, a unified framework is developed, allowing production and preventive maintenance to be jointly considered. We use an age-dependent optimization model based on the minimization of an overall cost function, including inventory holdings, lost sales, preventive and corrective maintenance costs. We provide optimality conditions for the manufacturing systems considered, and use numerical methods to obtain an optimal preventive maintenance policy and the relevant age-dependent threshold level production policy. In this work, this policy is called the multiple threshold levels hedging point policy. We include numerical examples and sensitivity analyses to illustrate the importance and the effectiveness of the proposed methodology. Compared with other available optimal production and maintenance policies, the numerical solution obtained shows that the proposed age-dependent optimal production and maintenance policies significantly reduce the overall cost incurred.     

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.     

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.     

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.     

Production lot sizing with process deterioration and machine breakdown

The paper presents a generalized economic manufacturing quantity model for an unreliable production system in which the production facility may shift from an ‘in-control’ state to an ‘out-of-control’ state at any random time (when it starts producing defective items) and may ultimately break down afterwards. If a machine breakdown occurs during a production run, then corrective repair is done; otherwise, preventive repair is performed at the end of the production run to enhance the system reliability. The proposed model is formulated assuming that the time to machine breakdown, corrective and preventive repair times follow arbitrary probability distributions. However, the criteria for the existence and uniqueness of the optimal production time are derived under general breakdown and uniform repair time (corrective and preventive) distributions. The optimal production run time is determined numerically and the joint effect of process deterioration, machine breakdowns and repairs (corrective and preventive) on the optimal decisions is investigated for a numerical example.     

Hierarchical decision making in production and repair/replacement planning with imperfect repairs under uncertainties

In this paper, we analyse an optimal production, repair and replacement problem for a manufacturing system subject to random machine breakdowns. The system produces parts, and upon machine breakdown, either an imperfect repair is undertaken or the machine is replaced with a new identical one. The decision variables of the system are the production rate and the repair/replacement policy. The objective of the control problem is to find decision variables that minimize total incurred costs over an infinite planning horizon. Firstly, a hierarchical decision making approach, based on a semi-Markov decision model (SMDM), is used to determine the optimal repair and replacement policy. Secondly, the production rate is determined, given the obtained repair and replacement policy. Optimality conditions are given and numerical methods are used to solve them and to determine the control policy. We show that the number of parts to hold in inventory in order to hedge against breakdowns must be readjusted to a higher level as the number of breakdowns increases or as the machine ages. We go from the traditional policy with only one high threshold level to a policy with several threshold levels, which depend on the number of breakdowns. Numerical examples and sensitivity analyses are presented to illustrate the usefulness of the proposed approach.     

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.     

Time and inventory dependent optimal maintenance policies for single machine workstations: An MDP approach

In this work the problem of obtaining an optimal maintenance policy for a single-machine, single-product workstation that deteriorates over time is addressed, using Markov Decision Process (MDP) models. Two models are proposed. The decision criteria for the first model is based on the cost of performing maintenance, the cost of repairing a failed machine and the cost of holding inventory while the machine is not available for production. For the second model the cost of holding inventory is replaced by the cost of not satisfying the demand. The processing time of jobs, inter-arrival times of jobs or units of demand, and the failure times are assumed to be random. The results show that in order to make better maintenance decisions the interaction between the inventory (whether in process or final), and the number of shifts that the machine has been working without restoration, has to be taken into account. If this interaction is considered, the long-run operational costs are reduced significantly. Moreover, structural properties of the optimal policies of the models are obtained after imposing conditions on the parameters of the models and on the distribution of the lifetime of a recently restored machine.     

An interactive fuzzy goal programming approach for multi-period multi-product production planning problem

This study addresses an interactive multiple fuzzy goal programming (FGP) approach to the multi-period multi-product (MPMP) production planning problem in an imprecise environment. The proposed model attempts to simultaneously minimize total production costs, rates of changes in labor levels, and maximizing machine utilization, while considering individual production routes of parts, inventory levels, labor levels, machine capacity, warehouse space, and the time value of money. Piecewise linear membership functions are utilized to represent decision maker’s (DM’s) overall satisfaction levels. A numerical example demonstrates the feasibility of applying the proposed model to the MPMP problem. Furthermore, the proposed interactive approach facilitates the DM with a systematic framework of decision making process which enables DM to modify the search direction to reach the most satisfactory results during solving process.     

马尔科夫决策过程在R/M系统库存控制中的应用

给出了有限阶段R/M(再制造/制造)系统集成库存模式,利用马尔科夫决策理论对库存容量有限、具有随机再制造零部件的R/M系统集成库存进行研究,考虑再制造零部件单位成本、新零部件可变费用和固定费用、超过库存容量的那部分再制造零部件的附加费用及有缺货赔偿的情况,给出了马尔科夫决策过程模型,得到了随机最优控制策略.     

Production and replacement policies for a deteriorating manufacturing system under random demand and quality

This work investigates the production planning of an unreliable deteriorating manufacturing system under uncertainties. The effect of the deterioration phenomenon on the machine is mainly observed in its availability and the quality of the parts produced, with the rates of failure and defectives increasing with the age of the machine. The option to replace the machine should be considered to mitigate the effect of deterioration in order to ensure long-term satisfaction of demand. The objective of this paper is to find the production rate and the replacement policy that minimize the total discounted cost, which includes inventory, backlog, production, repair and replacement costs, over an infinite planning horizon. We formulate the stochastic control problem in the framework of a semi-Markov decision process to consider the machine's history. The integration of random demand and quality behaviour led us to propose a new modeling approach by developing optimality conditions in terms of a second-order approximation of Hamilton–Jacobi–Bellman (HJB) equations. Numerical methods are used to obtain the optimal control policies. Finally, a numerical example and a sensitivity analysis are presented in order to illustrate and confirm the structure of the optimal solution obtained.     

提前期不确定条件下的预防性维修备件存储模型研究

在考虑预防性维修周期和提前期不确定的条件下,分别研究备件存储与其相关的维修费用、缺货费用、库存费用以及订购费用等四种费用之间的关系,明确了备件存储量对各项费用的影响.以各项费用总和最小化为目标,构建了提前期不确定条件下的预防性维修备件存储模型.通过备件存储模型的构建,对备件存储过程中的各项成本进行分析,以期对备件库存策略的确定给出一种解决方案.     

An interactive method for inventory control with fuzzy lead-time and dynamic demand

Normally, the real-world inventory control problems are imprecisely defined and human interventions are often required to solve these decision-making problems. In this paper, a realistic inventory model with imprecise demand, lead-time and inventory costs have been formulated and an inventory policy is proposed to minimize the cost using man–machine interaction. Here, demand increases with time at a decreasing rate. The imprecise parameters of lead-time, inventory costs and demand are expressed through linear/non-linear membership functions. These are represented by different types of membership functions, linear or quadratic, depending upon the prevailing supply condition and marketing environment. The imprecise parameters are first transformed into corresponding interval numbers and then following the interval mathematics, the objective function for average cost is changed into respective multi-objective functions. These functions are minimized and solved for a Pareto-optimum solution by interactive fuzzy decision-making procedure. This process leads to man–machine interaction for optimum and appropriate decision acceptable to the decision maker’s firm. The model is illustrated numerically and the results are presented in tabular forms.     

Optimising a general repair kit problem with a service constraint

Field services are a particular type of after-sales service performed at the customer’s location where technicians repair malfunctioning machines. The inventory decisions about which spare part types to take to the repair site and in what quantities is called the repair kit problem. This problem is characterized by an order-based performance measure since a customer is only satisfied when all required spare parts are available to fix the machine. As a result, the service level in the decision making process is defined as a job fill rate. In this paper we derive a closed-form expression for the expected service level and total costs for the repair kit problem in a general setting, where multiple units of each part type can be used in a multi-period problem. Such an all-or-nothing strategy is a new characteristic to investigate, but commonly used in practice. Namely, items are only taken from the inventory when all items to perform the repair are available in the right quantity. We develop a new algorithm to determine the contents of the repair kit both for a service and cost model while incorporating this new expression for the job fill rate. We show that the algorithm finds solutions which differ on average 0.2% from optimal costs. We perform a case study to test the performance of the algorithm in practice. Our approach results in service level improvements of more than 30% against similar holding costs.     

Fuzzy extensions to Integer Programming models of cell-formation problems in machine scheduling

Cell formation has received much attention from academicians and practitioners because of its strategic importance to modern manufacturing practices. Existing research on cell formation problems using integer programming (IP) has achieved the target of solving problems that simultaneously optimise: (a) cell formation, (b) machine-cell allocation, and (c) part-machine allocation. This paper will present extensions of the IP model where part-machine assignment and cell formation are addressed simultaneously, and also a significant number of constraints together with an enhanced objective function are considered. The main study examines the integration of inter-cell movements of parts and machine set-up costs within the objective function, and also the combination of machine set-up costs associated with parts revisiting a cell when part machine operation sequence is taken into account. The latter feature incorporates a key set of constraints which identify the number of times a part travels back to a cell for a later machine operation. Due to two main drawbacks of IP modelling for cell formation, i.e. (a) only one objective function can be involved and (b) the decision maker is required to specify precisely goals and constraints, fuzzy elements like fuzzy constraints and fuzzy goals will be considered in the proposed model. Overall the paper will not only include an extended and enhanced integer programming model for assessing the performance of cell formation, but also perform a rigorous study of fuzzy integer programming and demonstrate the feasibility of achieving better and faster clustering results using fuzzy theory.     

A Markov decision algorithm for optimal inspections and revisions in a maintenance system with partial information

This paper deals with a gradually deteriorating equipment whose actual degree of deterioration can be revealed by inspections only. An inspection can be succeeded by a revision depending on the system's degree of deterioration. In the absence of inspections and revisions, the working condition of the system evolves according to a Markov chain whose changes of state are not observable with the possible exception of a breakdown. Examples of this model include production machines subject to stochastic breakdowns, and maintenance of communication systems. The cost structure of the model consists of inspection, revision and operating costs. It is intuitively reasonable that in many applications a simple control-limit rule will be optimal. Such a rule prescribes a revision only when inspection reveals that the degree of deterioration has exceeded some critical level. A special-purpose Markov decision algorithm operating on the class of control-limit rules is developed for the computation of an average cost optimal schedule of inspections and revisions.     

A bivariate optimal replacement policy for a cold standby repairable system with preventive repair

In this paper, the repair-replacement problem for a deteriorating cold standby repairable system is investigated. The system consists of two dissimilar components, in which component 1 is the main component with use priority and component 2 is a supplementary component. In order to extend the working time and economize the running cost of the system, preventive repair for component 1 is performed every time interval T, and the preventive repair is “as good as new”. As a supplementary component, component 2 is only used at the time that component 1 is under preventive repair or failure repair. Assumed that the failure repair of component 1 follows geometric process repair while the repair of component 2 is “as good as new”. A bivariate repair-replacement policy (T, N) is adopted for the system, where T is the interval length between preventive repairs, and N is the number of failures of component 1. The aim is to determine an optimal bivariate policy (T, N)^∗ such that the average cost rate of the system is minimized. The explicit expression of the average cost rate is derived and the corresponding optimal bivariate policy can be determined analytically or numerically. Finally, a Gamma distributed example is given to illustrate the theoretical results for the proposed model.     

Economic and economic-statistical design of a chi-square chart for CBM

In this paper, the economic and economic-statistical design of a χ² chart for a maintenance application is considered. The machine deterioration process is described by a three-state continuous time Markov chain. The machine state is unobservable, except for the failure state. To avoid costly failures, the system is monitored by a χ² chart. The observation process stochastically related to the machine condition is assumed to be multivariate, normally distributed. When the chart signals, full inspection is performed to determine the actual machine condition. The system can be preventively replaced at a sampling epoch and must be replaced upon failure; preventive replacement costs less than failure replacement. The objective is to find the optimal control chart parameters that minimize the long-run average maintenance cost per unit time. For the economic-statistical design, an additional constraint guaranteeing the occurrence of the true alarm signal on the chart before failure with given probability is considered. For both designs, the objective function is derived using renewal theory.     

An integrated model for lot sizing with supplier selection and quantity discounts

Good inventory management is essential for a firm to be cost competitive and to acquire decent profit in the market, and how to achieve an outstanding inventory management has been a popular topic in both the academic field and in real practice for decades. As the production environment getting increasingly complex, various kinds of mathematical models have been developed, such as linear programming, nonlinear programming, mixed integer programming, geometric programming, gradient-based nonlinear programming and dynamic programming, to name a few. However, when the problem becomes NP-hard, heuristics tools may be necessary to solve the problem. In this paper, a mixed integer programming (MIP) model is constructed first to solve the lot-sizing problem with multiple suppliers, multiple periods and quantity discounts. An efficient Genetic Algorithm (GA) is proposed next to tackle the problem when it becomes too complicated. The objectives are to minimize total costs, where the costs include ordering cost, holding cost, purchase cost and transportation cost, under the requirement that no inventory shortage is allowed in the system, and to determine an appropriate inventory level for each planning period. The results demonstrate that the proposed GA model is an effective and accurate tool for determining the replenishment for a manufacturer for multi-periods.     

An inventory model for non-instantaneous deteriorating items with quadratic demand rate and shortages under trade credit policy

noindent In this paper, we propose an appropriate inventory model for non-instantaneous deteriorating items over quadratic demand rate with permissible delay in payments and time dependent deterioration rate. In this model, the completely backlogged shortages are allowed. In several existing results, the authors discussed that the deterioration rate is constant in each cycle. However, the deterioration rate of items are not constant in real world applications. Motivated by this fact, we consider that the items are deteriorated with respect to time. To minimize the total relevant inventory cost, we prove some useful theorems to illustrate the optimal solutions by finding an optimal cycle time with the necessary and enough conditions for the existence and uniqueness of the optimal solutions. Finally, we discuss the numerical instance and sensitivity of the proposed model.