Integrated production, quality control and condition-based maintenance for imperfect production systems

•We study the joint design of production, quality and maintenance control policies.•The production system is subject to both reliability and quality deteriorations.•Both the condition monitoring and the quality information feedback are incorporated into the maintenance decision-making process.•A sim...

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Vydáno v:Reliability engineering & system safety Ročník 175; s. 251 - 264
Hlavní autoři: Cheng, Guo Qing, Zhou, Bing Hai, Li, Ling
Médium: Journal Article
Jazyk:angličtina
Vydáno: Barking Elsevier Ltd 01.07.2018
Elsevier BV
Témata:
Computer simulation
Condition-based maintenance
Industrial production
Inspection
Inventory management
Lot sizing
Monte Carlo simulation
Optimization
Preventive maintenance
Production-inventory system
Quality control
Reliability aspects
Reliability engineering
Repair & maintenance
Response surface methodology
Sensitivity analysis
Simulation-based optimization
Lot sizing
Simulation-based optimization
Condition-based maintenance
Production-inventory system
Quality control
ISSN:0951-8320, 1879-0836
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Shrnutí:•We study the joint design of production, quality and maintenance control policies.•The production system is subject to both reliability and quality deteriorations.•Both the condition monitoring and the quality information feedback are incorporated into the maintenance decision-making process.•A simulation-based optimization approach is proposed to solve the complex stochastic problem. This paper considers an integrated problem of production lot sizing, quality control and condition-based maintenance for an imperfect production system subject to both reliability and quality degradations. The system produces a single type of product to meet constant demand. To provide protection to the stock against uncertainties, a make-to-stock production policy is employed. The condition-based maintenance policy consists in carrying out inspections at the end of production runs to evaluate system condition and performing imperfect preventive maintenance if detected degradation level exceeds the threshold. The quality control is performed by using 100% inspection policy to obtain the proportion of defectives. Based on the quality information feedback, an overhaul action is conducted once the proportion reaches a given threshold during production runs. The aim of this paper is to jointly optimize the lot size, the inventory threshold, the preventive maintenance and overhaul thresholds such that the total cost per unit time is minimized. A stochastic mathematical model is formulated and solved by a simulation-based optimization approach coupling Monte Carlo Simulation and Response Surface Methodology. Finally, an illustrative example and sensitivity analyses are provided to demonstrate the proposed model.
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ISSN:0951-8320
1879-0836
DOI:10.1016/j.ress.2018.03.025