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Article
Publication date: 14 May 2018

Guy Richard Kibouka, Donatien Nganga-Kouya, Jean-Pierre Kenné, Vladimir Polotski and Victor Songmene

The purpose of this paper is to find the optimal production and setup policies for a manufacturing system that produces two different types of parts. The manufacturing…

Abstract

Purpose

The purpose of this paper is to find the optimal production and setup policies for a manufacturing system that produces two different types of parts. The manufacturing system consists of one machine subject to random failures and repairs. Reconfiguring the machine to switch production from one type of product to another generates a non-production time and a significant cost.

Design/methodology/approach

This paper proposes an approach based on the development of optimal production and setup policies, taking into account the possibilities of undertaking the setup for all modes of the machine, and covering them at the end of setup. New optimality conditions are developed in terms of modified Hamilton-Jacobi-Bellman (HJB) equations and recursive numerical methods are applied to solve such equations.

Findings

The proposed approach led to determine more realistic production rates of both parts and setup sequences for the different modes of the machine that significantly influence the inventory and the system capacity. A numerical example and sensitivity analysis are used to determine the structure of the optimal policies and to show the helpfulness and robustness of the results obtained.

Practical implications

Following the steps of the proposed approach will provide the control policies for industrial manufacturing systems with setup permitted at all modes of the machine, and when the setup does not necessarily restore the machine to its operational mode. The proposed optimal policy takes into account the stochastic nature of the machine mode at the end of setup and we show that ignoring it leads to non-natural policies and underestimates significantly the safety stock thresholds.

Originality/value

Considering the assumptions presented in this paper leads to a new structure of the control laws for the production planning of manufacturing systems with setup.

Details

Journal of Quality in Maintenance Engineering, vol. 24 no. 2
Type: Research Article
ISSN: 1355-2511

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Article
Publication date: 1 March 2003

J.P. Kenné and E.K. Boukas

This paper deals with the production and preventive maintenance planning control problem for a multi‐machine flexible manufacturing system (FMS). A two‐level hierarchical…

Abstract

This paper deals with the production and preventive maintenance planning control problem for a multi‐machine flexible manufacturing system (FMS). A two‐level hierarchical control model is developed according to the discrepancy between the time scale of the discounting cost event and one of the machine state processes. The proposed model extends the classical singular perturbation approach by considering age‐dependent machine failure rates and controlling both production and preventive maintenance rates. We replace the stochastic optimal control problem by a deterministic one termed limiting control problem. With this approach, we compute an age‐dependent near‐optimal control policy of the stochastic initial control problem from the optimal solution of the equivalent limiting control problem. A numerical example is used to illustrate the procedure and to show the reduction of the control problem size.

Details

Journal of Quality in Maintenance Engineering, vol. 9 no. 1
Type: Research Article
ISSN: 1355-2511

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Article
Publication date: 16 August 2011

Achille N. Njike, Robert Pellerin and Jean Pierre Kenne

This paper seeks to develop an optimal stochastic control model where interactive feedback consists of the quantity of flawless and defective products. The main objective…

Abstract

Purpose

This paper seeks to develop an optimal stochastic control model where interactive feedback consists of the quantity of flawless and defective products. The main objective of this study is to minimize the expected discounted overall cost due to maintenance activities, inventory holding and backlogs.

Design/methodology/approach

The model differs from similar research projects in that, instead of age‐dependent machine failure, it considers only defective products as feedback into the optimal model for maintenance and production planning. In this paper a near optimal control policy of the system through numerical techniques is obtained.

Findings

In this paper, a new model in which the system's retroaction is the quantity of defective products is presented, considering that defective products are a consequence of global manufacturing system deterioration. Instead of taking into account machine failure and human error separately, it considers a defect in product as being the consequence of a combined failure; this consideration allows one to be more realistic by merging all failure parameters into a single one. A new stochastic control model, which focuses on defective products, inventory, and backlog, has been developed.

Research limitations/implications

This approach extended the concept of hedging point policy to the quantity of defective products combined with preventive and corrective maintenance strategies. The control policy obtained has a bang bang structure and is completely known for given parameters.

Originality/value

The integration of maintenance and production strategies has been mainly focused on the machine. Many research projects have been focusing on the age when dealing with machine failure. It is considered as the main target of the cost reduction in maintenance engineering departments. The originality of this paper is the taking into account of all operational failures into the same optimization model. It brings a value added to high level of maintenance and for operation managers who need to consider all failure parameters before taking decisions related to cost.

Details

Journal of Quality in Maintenance Engineering, vol. 17 no. 3
Type: Research Article
ISSN: 1355-2511

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Article
Publication date: 25 September 2009

Jean‐François Boulet, Ali Gharbi and Jean‐Pierre Kenné

The purpose of this article is to consider a corrective and preventive maintenance model with a view to both minimizing cost and maximizing system availability.

Abstract

Purpose

The purpose of this article is to consider a corrective and preventive maintenance model with a view to both minimizing cost and maximizing system availability.

Design/methodology/approach

The proposed experimental multiobjective approach combines a simulation model and a statistical method to determine the best system parameters. The desirability function is used to convert a multiresponse problem into a maximization problem with a single aggregate measure. The model examined is based on a m identical machines system subject to unpredictable breakdown and repair, and the maintenance strategy used is based on the existing block‐replacement policy, which consists in replacing components upon failure or preventively, at scheduled intervals (T). Spare part inventory management is based on the (S, Q) model, whereby an order is placed when the replacement stock level drops below a given safety threshold level (S). At that time, a replacement part quantity (Q) is ordered, and is received after a stochastic lead time (τ).

Findings

The proposed model jointly minimizes the overall maintenance cost and maximizes system availability using a multiobjective optimization desirability function.

Practical implications

The multiobjective model can be used in a real manufacturing environment to help business decision makers determine the best compromise system parameters and adjust them to obtain desired response variables (overall production cost and system availability).

Originality/value

The proposed model allows the simultaneous optimization of two response variables, and determines the best system parameter compromise between the system cost minimization and the system availability maximization.

Details

Journal of Quality in Maintenance Engineering, vol. 15 no. 4
Type: Research Article
ISSN: 1355-2511

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Article
Publication date: 27 July 2020

Mohamed Ali Kammoun, Zied Hajej and Nidhal Rezg

The main contribution of this manuscript is to suggest new approaches in order to deal with dynamic lot-sizing and maintenance problem under aspect energetic and risk…

Abstract

Purpose

The main contribution of this manuscript is to suggest new approaches in order to deal with dynamic lot-sizing and maintenance problem under aspect energetic and risk analysis. The authors introduce a new maintenance strategy based on the centroid approach to determine a common preventive maintenance plan for all machines to minimize the total maintenance cost. Thereafter, the authors suggest a risk analysis study further to unforeseen disruption of availability machines with the aim of helping the production stakeholders to achieve the obtained forecasting lot-size plan.

Design/methodology/approach

The authors tackle the dynamic lot-sizing problem using an efficient hybrid approach based on random exploration and branch and bound method to generate possible solutions. Indeed, the feasible solutions of random exploration method are used as input for branch and bound to determine the near-optimal solution of lot-size plan. In addition, our contribution to the maintenance part is to determine the optimal common maintenance plan for M machines based on a new algorithm called preventive maintenance (PM) periods means.

Findings

First, the authors have funded the optimal lot-size plan that should satisfy the random demand under service level requirement and energy constraint while minimizing the costs of production and inventory. Indeed, establishing a best lot-size plan is to determine the appropriate number of available machines and manufactured units per period. Second, for risk analysis study, the solution of subcontracting is proposed by specifying a maximum cost of subcontractor in the context of a calling of tenders.

Originality/value

For maintenance problem, the originality consists in regrouping the maintenance plans of M machines into only one plan. This approach lets us to minimize the total maintenance cost and reduces the frequent breaks of production. As a second part, this paper contributed to the development of a new risk analysis study further to unforeseen disruption of availability machines. This risk analysis developed a decision-making system, for production stakeholders, in order to achieve the forecasting lot-size plan and keeps its profitability, by specifying the unit cost threshold of subcontractor in the context of a calling of tender.

Details

International Journal of Quality & Reliability Management, vol. 37 no. 6/7
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 7 October 2014

Behnam Emami-Mehrgani, Sylvie Nadeau and Jean-Pierre Kenné

The analysis of the optimal production and preventive maintenance with lockout/tagout planning problem for a manufacturing system is presented in this paper. The…

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.

Details

Journal of Quality in Maintenance Engineering, vol. 20 no. 4
Type: Research Article
ISSN: 1355-2511

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Article
Publication date: 9 May 2016

Abdoulaye Badiane, Sylvie Nadeau, Jean-Pierre Kenné and Vladimir Polotski

The optimization of production imposes a review of facility maintenance policies. Accidents during maintenance activities are frequent, sometimes fatal and often…

Abstract

Purpose

The optimization of production imposes a review of facility maintenance policies. Accidents during maintenance activities are frequent, sometimes fatal and often associated with deficient or absent machinery lockout/tagout. Lockout/tagout is often circumvented in order to avoid what may be viewed as unnecessary delays and increased production costs. To reduce the dangers inherent in such practice, the purpose of this paper is to propose a production strategy that provides for machinery lockout/tagout while maximizing manufacturing system availability and minimizing costs.

Design/methodology/approach

The joint optimization problem of production planning, maintenance and safety planning is formulated and studied using a stochastic optimal control methodology. Hamilton-Jacobi-Bellman equations are developed and studied numerically using the Kushner approach based on finite difference approximation and an iterative policy improvement technique.

Findings

The analysis leads to a solution that suggests increasing the “comfortable” inventory level in order to provide the time required for lockout/tagout activities. It is also demonstrated that the optimization of lockout/tagout procedures is particularly important when the equipment is relatively new and the inventory level is minimal.

Research limitations/implications

This paper demonstrates that it is possible to integrate production, maintenance and lockout/tagout procedures into production planning while keeping manufacturing system cost objectives attainable as well as ensuring worker safety.

Originality/value

This integrated production and maintenance policy is unique and complements existing procedures by explicitly accounting for safety measures.

Details

Journal of Quality in Maintenance Engineering, vol. 22 no. 2
Type: Research Article
ISSN: 1355-2511

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Article
Publication date: 14 August 2017

Surya Prakash, Gunjan Soni and Ajay Pal Singh Rathore

The purpose of this paper is to assist a manufacturing firm in designing the closed-loop supply chain network under risks that are affecting its supply quality and…

Abstract

Purpose

The purpose of this paper is to assist a manufacturing firm in designing the closed-loop supply chain network under risks that are affecting its supply quality and logistics operations. The modeling approach adopted aims at the embedding supply chain risks in a closed-loop supply chain (CLSC) network design process and suggests optimal supply chain configuration and risk mitigation strategies.

Design/methodology/approach

The method proposes a closed-loop supply chain network and identifies the network parameter and variables required for closing the loop. Mixed-integer-linear-programming-based mathematical modeling approach is used to formulate the research problem. The solutions and test results are obtained from CPLEX solver.

Findings

The outcomes of the proposed model were demonstrated through a case study conducted in an Indian hospital furniture manufacturing firm. The modern supply chain is mapped to make it closed loop, and potential risks in its supply chain are identified. The supply chain network of the firm is redesigned through embedding risk in the modeling process. It was found that companies can be in great profit if they follow closed-loop practices and simultaneously keep a check on risks as well. The cost of making the supply chain risk averse was found to be insignificant.

Practical implications

Although the study was conducted in a practical case situation, the obtained results are not indiscriminate to the other circumstances. However, the approach followed and proposed methodology can be applied to many industries once a firm decides to redesign its supply chain for closing its loop or model under risks.

Originality/value

By using the identified CLSC parameters and applying the proposed network design methodology, a firm can design/redesign their supply chain network to counter the risk and accordingly come up with planned mitigation strategies to achieve a certain degree of robustness.

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Article
Publication date: 5 June 2017

Chandra Shekhar, Madhu Jain, Ather Aziz Raina and Javid Iqbal

The purpose of this paper is to study the performance metrics of redundant repairable machining system which is applicable in various systems like computer and…

Abstract

Purpose

The purpose of this paper is to study the performance metrics of redundant repairable machining system which is applicable in various systems like computer and communication system, manufacturing and production system, etc.

Design/methodology/approach

In the present investigation, the authors develop Markov model for the system consisting of identical active operating machines which are prone to breakdown. The operating machines are under the care of one permanent repair facility that provides time-sharing basis repair services. The maintenance is facilitated with the provision of standby machines of mixed type and permanent as well as additional repair facility. From the economic point of view, F-policy and N-policy to control the service and arrival of failed machines effectively are included.

Findings

For the performance analysis of the system in long run, the authors compute steady-state probabilities using product-type solution method recursively. Sensitivity analysis is performed numerically for various parameters by developing code in MATLAB.

Social implications

The performance prediction done may be helpful for the system designers and decision makers for the improvement of the existing machining systems in various industries.

Originality/value

Markovian model for the performance prediction of fault tolerant multi-identical operating and standby machines redundant system is developed in generic frameworks by incorporating many noble features which were not all taken together by other researchers working on the same lines. The key concepts incorporated for the modeling of the concerned system is: F-policy, N-policy, time-sharing, and sensitivity analysis of availability and cost function.

Details

International Journal of Quality & Reliability Management, vol. 34 no. 6
Type: Research Article
ISSN: 0265-671X

Keywords

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Article
Publication date: 2 October 2019

Jérémie Schutz, Anis Chelbi, Nidhal Rezg and Safa Ben Salem

The purpose of this paper is to deal with the problem of integration of production and maintenance policies. In this context, the authors consider production systems made…

Abstract

Purpose

The purpose of this paper is to deal with the problem of integration of production and maintenance policies. In this context, the authors consider production systems made of parallel machines producing a single product over a finite horizon made of equal periods for which a forecasted demand is known. The authors investigate the impact of switching production in case of failure of any given machine.

Design/methodology/approach

A mathematical model is first developed to find an optimal production plan which minimizes the average total storage, shortage and production costs. Then, using this optimal production plan and taking into account the influence of the production rate on the degradation of each machine, optimal preventive maintenance (PM) policies are proposed for the situations with and without switching.

Findings

Optimal production rates are determined for each production period and for each machine. Optimal PM periods are also computed for each machine.

Practical implications

Usually, in manufacturing systems, the production rate of a machine influences its failure rate. In case a machine fails, it takes a random time to repair it during which production is lost. The paper attempts to propose a switching policy (SP) according to which the lost production is compensated by all the other machines. The effects of the SP coupled with the PM strategy are shown through a numerical example.

Originality/value

Contrarily to previous works, the authors consider more realistic settings with a non-negligible random time for repairing failed machines. In order to compensate the lost production during the repair of a failed machine, a SP is proposed to transfer the load uniformly to all the other machines. As a result, those machines will produce at a higher production rate and will consequently have their failure rate increased. It will therefore be essential to determine an optimal PM schedule knowing that durations of these activities are not negligible. It is shown that the simultaneous implementation of periodic PM and load transfer in case of failure is the most economical integrated strategy.

Details

Journal of Quality in Maintenance Engineering, vol. 25 no. 4
Type: Research Article
ISSN: 1355-2511

Keywords

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