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Optimal lockout/tagout, preventive maintenance, human error and production policies of manufacturing systems with passive redundancy

Behnam Emami-Mehrgani (Department of Mechanical Engineering, École de technologie supérieure, Montreal, Canada)
Sylvie Nadeau (Department of Mechanical Engineering, École de technologie supérieure, Montreal, Canada)
Jean-Pierre Kenné (Department of Mechanical Engineering, École de technologie supérieure, Montreal, Canada)

Journal of Quality in Maintenance Engineering

ISSN: 1355-2511

Article publication date: 7 October 2014

634

Abstract

Purpose

The analysis of the optimal production and preventive maintenance with lockout/tagout planning problem for a manufacturing system is presented in this paper. The considered manufacturing system consists of two non-identical machines in passive redundancy producing one type of part. These machines are subject to random breakdowns and repairs. The purpose of this paper is to minimize production, inventory, backlog and maintenance costs over an infinite planning horizon; in addition, it aims to verify the influence of human reliability on the inventory levels for illustrating the importance of human error during the maintenance and lockout/tagout activities.

Design/methodology/approach

This paper is different compared to other research projects on preventive maintenance and lockout/tagout. The influence of human error on lockout/tagout as well as on preventive maintenance activities are presented in this paper. The preventive maintenance policy depends on the machine age. For the considered manufacturing system the optimality conditions are provided, and numerical methods are used to obtain machine age-dependent optimal control policies (production and preventive maintenance rates with lockout/tagout). Numerical examples and sensitivity analysis are presented to illustrate the usefulness of the proposed approach. The system capacity is described by a finite-state Markov chain.

Findings

The proposed model taking into account the preventive maintenance activities with lockout/tagout and human error jointly, instead of taking into account separately. It verifies the influence of human error during preventive maintenance and lockout/tagout activities on the optimal safety stock levels using an extension of the hedging point structure.

Practical implications

The model proposed in this paper might be extended to manufacturing systems, but a number of conditions must be met to make effective use of it.

Originality/value

The originality of this paper is to consider the preventive maintenance activities with lockout/tagout and human error simultaneously. The control policy is obtained in order to find the solution for the considered manufacturing system. This paper also brings a new vision on the importance of human reliability during preventive maintenance and lockout/tagout activities.

Keywords

Acknowledgements

The authors gratefully acknowledge the financial support of this work from the following agencies: Natural Sciences and Engineering Research Council of Canada (NSERC); Réseau de Recherche en Santé et en Sécurité du Travail du Québec (RRSSTQ); Fonds de la Recherche en Santé – Québec (FRSQ); Fonds Québécois de la Recherche sur la Société et la Culture (FQRSC); Fonds Québécois de la Recherche sur la Nature et les Technologies (FQRNT), Institut de Recherche Robert-Sauvé en Santé et en Sécurité du Travail (IRSST) and Équipe de Recherche en Sécurité du Travail (EREST).

Citation

Emami-Mehrgani, B., Nadeau, S. and Kenné, J.-P. (2014), "Optimal lockout/tagout, preventive maintenance, human error and production policies of manufacturing systems with passive redundancy", Journal of Quality in Maintenance Engineering, Vol. 20 No. 4, pp. 453-470. https://doi.org/10.1108/JQME-10-2012-0035

Publisher

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Emerald Group Publishing Limited

Copyright © 2014, Emerald Group Publishing Limited

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