Scheduling the maintenance on a single machine

This paper considers a single machine scheduling problem with preventive maintenance. In many cases, a machine must be maintained after it continuously works for a period of time. But most papers in the literature ignore non-availability of the machine. For this reason, this paper studies the problem of scheduling processing of jobs and maintenance of machine simultaneously. The objective is to minimise total completion time of jobs. The problem is proved to be NP-hard in the strong sense. Three heuristic algorithms and a branch and bound algorithm are proposed. Computational experiments are done to evaluate the effectiveness of the algorithms.     

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.     

Single machine scheduling problem with two synergetic agents and piece-rate maintenance

This paper attempts to study on the single machine scheduling problems with two synergetic agents, each has a set of nonpreemptive jobs and a regular objective function depending on the completion times of its jobs only. It is not only necessary to satisfy the constraints of each agents objective function, it is necessary to minimize an aggregate increasing objective function of two agents’ objective function. Furthermore, this paper proposes a new kind of machine maintenance: piece-rate maintenance, which depicts the scenario that machine maintenance is implemented once every a fixed number of jobs is completed. Hence, it explores into the single machine scheduling problems with two synergetic agents and piece-rate maintenance. If the regular objective function of each job is polynomial, it can be observed that these problems are all polynomially solvable.     

Integrated production and maintenance planning for parallel machine system considering cost of rejection

Production scheduling and maintenance planning have interdependencies but been often considered and optimized independently in practice and in the literature. Furthermore, product quality has direct relationship with maintenance planning. This paper proposes an integrated approach for production scheduling and maintenance planning for parallel machine system considering the effect of cost of rejection. The approach aims to determine optimal production schedule and maintenance plan such that overall operations cost is minimized. A simulation-based optimization approach is used to solve the problem. A numerical investigation is performed to illustrate the approach. The integrated approach shows between 0.6 and 35.8% improvement in term of overall operations cost over independent approach for various scenarios. The results indicate that simultaneous consideration of production scheduling and maintenance planning results into better system performance.     

Machine scheduling performance with maintenance and failure

In manufacturing control, machine scheduling research has mostly dealt with problems either without maintenance or with deterministic maintenance when no failure can occur. This can be unrealistic in practical settings. In this work, an experimental model is developed to evaluate the effect of corrective and preventive maintenance schemes on scheduling performance in the presence of machine failure where the scheduling objective is to minimize schedule duration. We show that neither scheme is clearly superior, but that the applicability of each depends on several system parameters as well as the scheduling environment itself. Further, we show that parameter values can be chosen for which preventive maintenance does better than corrective maintenance. The results provided in this study can be useful to practitioners and to system or machine administrators in manufacturing and elsewhere.     

Optimum policy for a production system with major repair and preventive maintenance

This study applies periodic preventive maintenance (PM) to a repairable production system with major repairs conducted after a failure. This study considers failed PM due to maintenance workers incorrectly performing PM and damages occurring after PM. Therefore, three PM types are considered: imperfect PM, perfect PM and failed PM. Imperfect PM has the same failure rate as that before PM, whereas perfect PM makes restores the system perfectly. Failed PM results in system deterioration and major repairs are required. The probability that PM is perfect or failed depends on the number of imperfect maintenance operations conducted since the previous renewal cycle. Mathematical formulas for expected total production cost per unit time are generated. Optimum PM time that minimizes cost is derived. Various special cases are considered, including the maintenance learning effect. A numerical example is given.     

Complexity results and approximation algorithms for the two machine no-wait flow-shop with limited machine availability

The scheduling problems studied in this paper concern a two-machine no-wait flow shop problem with limited machine availability. In this model, we assume that machines may not always be available, for example because of preventive maintenance. We only consider the deterministic case where the unavailable periods are known in advance. The objective function considered is the maximum completion time (C_max). We prove that the problem is NP-hard even if only one non-availability period occurs on one of machines, and NP-hard in the strong sense for arbitrary numbers of non-availability periods. We also provide heuristic algorithms with error bounding analysis.     

Economic production lot-sizing for an unreliable machine under imperfect age-based maintenance policy

This paper is concerned with the joint determination of both economic production quantity and preventive maintenance (PM) schedules under the realistic assumption that the production facility is subject to random failure and the maintenance is imperfect. The manufacturing system is assumed to deteriorate while in operation, with an increasing failure rate. The system undergoes PM either upon failure or after having reached a predetermined age, whichever of them occurs first. As is often the case in real manufacturing applications, maintenance activities are imperfect and unable to restore the system to its original healthy state. In this work, we propose a model that could be used to determine the optimal number of production runs and the sequence of PM schedules that minimizes the long-term average cost. Some useful properties of the cost function are developed to characterize the optimal policy. An algorithm is also proposed to find the optimal solutions to the problem at hand. Numerical results are provided to illustrate both the use of the algorithm in the study of the optimal cost function and the latter’s sensitivity to different changes in cost factors.     

Optimal economic production quantity policy for imperfect process with imperfect repair and maintenance

This study integrates maintenance and production programs with the economic production quantity (EPQ) model for an imperfect process involving a deteriorating production system with increasing hazard rate: imperfect repair and rework upon failure (out of control state). The imperfect repair performs some restorations and restores the system to an operating state (in-control state), but leaves its failure until perfect preventive maintenance (PM) is performed. There are two types of PM, namely imperfect PM and perfect PM. The probability that perfect PM is performed depends on the number of imperfect maintenance operations performed since the last renewal cycle. Mathematical formulas are obtained for deriving the expected total cost. For the EPQ model, the optimum run time, which minimizes the total cost, is discussed. Various special cases are considered, including the maintenance learning effect. Finally, a numerical example is presented to illustrate the effects of PM, setup, breakdown and holding costs.     

多部件系统故障预防工作的组合优化

研究了实践中常见的四种预防工作组合类型,即定时维修、功能检测、使用检查及检查与定时维修的组合策略,以单位时间维修费用最小为目标建立了多部件故障预防工作的组合优化模型.在此基础上,提出了两个故障预防工作的组合优化算法,并给出了计算示例以说明模型和算法的性能.     

A numerical method to approximate optimal production and maintenance plan in a flexible manufacturing system

The simultaneous planning of the production and the maintenance in a flexible manufacturing system is considered in this paper. The manufacturing system is composed of one machine that produces a single product. There is a preventive maintenance plan to reduce the failure rate of the machine. This paper is different from the previous researches in this area in two separate ways. First, the failure rate of the machine is supposed to be a function of its age. Second, we assume that the demand of the manufacturing product is time dependent and its rate depends on the level of advertisement on that product. The objective is to maximize the expected discounted total profit of the firm over an infinite time horizon. In the process of finding a solution to the problem, we first characterize an optimal control by introducing a set of Hamilton–Jacobi–Bellman partial differential equations. Then we realize that under practical assumptions, this set of equations can not be solved analytically. Thus to find a suboptimal control, we approximate the original stochastic optimal control model by a discrete-time deterministic optimal control problem. Then proposing a numerical method to solve the steady state Riccati equation, we approximate a suboptimal solution to the problem.     

Optimizing Preventive Maintenance Models

We deal with the problem of scheduling preventive maintenance (PM) for a system so that, over its operating life, we minimize a performance function which reflects repair and replacement costs as well as the costs of the PM itself. It is assumed that a hazard rate model is known which predicts the frequency of system failure as a function of age. It is also assumed that each PM produces a step reduction in the effective age of the system. We consider some variations and extensions of a PM scheduling approach proposed by Lin et al. [6]. In particular we consider numerical algorithms which may be more appropriate for hazard rate models which are less simple than those used in [6] and we introduce some constraints into the problem in order to avoid the possibility of spurious solutions. We also discuss the use of automatic differentiation (AD) as a convenient tool for computing the gradients and Hessians that are needed by numerical optimization methods. The main contribution of the paper is a new problem formulation which allows the optimal number of occurrences of PM to be determined along with their optimal timings. This formulation involves the global minimization of a non-smooth performance function. In our numerical tests this is done via the algorithm DIRECT proposed by Jones et al. [19]. We show results for a number of examples, involving different hazard rate models, to give an indication of how PM schedules can vary in response to changes in relative costs of maintenance, repair and replacement. Part of this work was carried out while the first author was a Visiting Professor in the Department of Mechanical Engineering at the University of Alberta in December 2003.     

Modelling preventive maintenance for deteriorating repairable systems

This paper is concerned with practical methods for the analysisand modelling of data for repairable systems which are subjectto preventive maintenance (PM) and still have an increasingrate of occurrence of failures. Aspects of testing for trendand fitting a nonhomogeneous Poission process to data are discussedModels for scheduling preventive maintenance to minimize costor maximize availability are proposed. They show that the optimalPM cycle interval for these systems decreases with increasingequipment age. One-cycle and two-cycle finite-time-zone replacementmodels are also developed to decide the optimal time for replacingthe equipment in current use.     

A branch and bound algorithm to minimize total tardiness of jobs in a two identical-parallel-machine scheduling problem with a machine availability constraint

This research focuses on the problem of scheduling jobs on two identical parallel machines that are not continuously available with the objective of minimizing total tardiness. After processing a given number of jobs, each machine requires a preventive maintenance task, during which the machine cannot process jobs. We present dominance properties and lower bounds, and develop a branch and bound algorithm using these properties and lower bounds as well as an upper bound obtained from a heuristic algorithm. Performance of the algorithm is evaluated through a series of computational experiments on randomly generated instances and results are reported.     

Approximation schemes for parallel machine scheduling with availability constraints

We investigate the problems of scheduling n weighted jobs to m parallel machines with availability constraints. We consider two different models of availability constraints: the preventive model, in which the unavailability is due to preventive machine maintenance, and the fixed job model, in which the unavailability is due to a priori assignment of some of the n jobs to certain machines at certain times. Both models have applications such as turnaround scheduling or overlay computing. In both models, the objective is to minimize the total weighted completion time. We assume that m is a constant, and that the jobs are non-resumable.For the preventive model, it has been shown that there is no approximation algorithm if all machines have unavailable intervals even if w_i=p_i for all jobs. In this paper, we assume that there is one machine that is permanently available and that the processing time of each job is equal to its weight for all jobs. We develop the first polynomial-time approximation scheme (PTAS) when there is a constant number of unavailable intervals. One main feature of our algorithm is that the classification of large and small jobs is with respect to each individual interval, and thus not fixed. This classification allows us (1) to enumerate the assignments of large jobs efficiently; and (2) to move small jobs around without increasing the objective value too much, and thus derive our PTAS. Next, we show that there is no fully polynomial-time approximation scheme (FPTAS) in this case unless P=NP.For the fixed job model, it has been shown that if job weights are arbitrary then there is no constant approximation for a single machine with 2 fixed jobs or for two machines with one fixed job on each machine, unless P=NP. In this paper, we assume that the weight of a job is the same as its processing time for all jobs. We show that the PTAS for the preventive model can be extended to solve this problem when the number of fixed jobs and the number of machines are both constants.     

具有可变配送费用和固定配送时刻的单机排序问题

研究了单机环境下生产与配送的协同排序问题.有多个工件需要在一台机器上进行加工,加工完的工件需要分批配送到一个客户.每批工件只能在固定的几个配送时刻出发,不同的配送时刻对应着不同的配送费用.我们的目标是找到生产与配送的协同排序,极小化排序的时间费用与配送费用的加权和.研究了排序理论中主要的四个目标函数,构建了单机情况下的具体模型,分析了问题的复杂性,对于配送费用单调非增的情况给出了它们的最优算法.     

Single machine scheduling with general job-dependent aging effect and maintenance activities to minimize makespan

This paper considers single machine scheduling with an aging effect in which the processing time of a job depends on its position in a sequence. It is assumed that aging ratios are job-dependent and machine can be maintained some times in a schedule. After a maintenance activity, machine will be restored to its initial condition. The processing of jobs and the maintenance activities of machine are scheduled simultaneously. The objective is to schedule the jobs and the maintenance activities, so as to minimize the makespan. We provide a polynomial time algorithm to solve the problem.     

On scheduling an unbounded batch machine

A batch machine is a machine that can process up to c jobs simultaneously as a batch, and the processing time of the batch is equal to the longest processing time of the jobs assigned to it. In this paper, we deal with the complexity of scheduling an unbounded batch machine, i.e., c=+∞. We prove that minimizing total tardiness is binary NP-hard, which has been an open problem in the literature. Also, we establish the pseudopolynomial solvability of the unbounded batch machine scheduling problem with job release dates and any regular objective. This is distinct from the bounded batch machine and the classical single machine scheduling problems, most of which with different release dates are unary NP-hard. Combined with the existing results, this paper provides a nearly complete mapping of the complexity of scheduling an unbounded batch machine.     

Order acceptance and due-date quotation in low machine rates

In real manufacturing environments, some customer orders include multiple jobs. However, a single due-date should be assigned to each order. Further, machine processing rate is not constant at all times. In effect, in many manufacturing operations, the machine processing rate decreases to a subnormal level during time and needs a special type of maintenance to bring the normal state back. Due to this reduction in capacity, production schedulers may decide to reject some orders. In this paper, the novel extensive problem of selecting a subset of orders, assigning due-dates to selected orders, scheduling the selected orders and jobs within each one, and scheduling the rate-modifying maintenance is studied. The objective function is minimizing total cost of lost-sales of rejected orders together with due-date length and maximum of earliness and tardiness of selected orders. The problem is proved polynomial and an optimal approach is developed.     

Scheduling a deteriorating maintenance activity on a single machine

We study a problem of scheduling a maintenance activity on a single machine. Following several recent papers, the maintenance is assumed to be deteriorating, that is, delaying the maintenance increases the time required to perform it. The following objective functions are considered: makespan, flowtime, maximum lateness, total earliness, tardiness and due-date cost, and number of tardy jobs. We introduce polynomial time solutions for all these problems.