Abstract
Purpose: We deal with the problem of the joint determination of optimal economic production quantity (EPQ) and optimal preventive maintenance (PM) for a system that can produce multiple products alternately. The objective is to find the optimal number of production cycles and the PM policy simultaneously by minimizing the cost model.Design/methodology/approach: Considering the products go through the system in a sequence and a complete run of all products forms a production cycle. In each cycle, beyond production time we also consider some reserve time for maintenance and setup, shortage and overproduction may occur. We study the integrated problem based on two PM policies, and explain the situation with the other PM policies. The delay – time concept is used to model PM decisions.Findings: Using the integrated EPQ and PM model, we can calculate the optimal production planning and PM schedule simultaneously, especially we consider multiple products in each production cycle, which is more practical and economic than previous works.Originality/value: In modern companies, the production planning and maintenance schedule share the same system, and traditional research about two activities is separated, that always generate conflicts, such as inadequate or excessive maintenance, and shortages, etc., so we develop the integrated EPQ and PM model to avoid these undesirable effects.
Highlights
In modern companies, optimal production planning and optimal maintenance schedule are always studied separately, conflict is generated inevitably since the two activities share the same system
Improper maintenance, or the other harmful effect caused by separated planning about production and maintenance, lots of researches of integrated production and maintenance are developed. Those researches can be categorized into two classes, the first one is about the integrated economic production quantity (EPQ) and maintenance model (Liu, Wang & Peng, 2015a), which is mainly based on the continuous modes of production, the second one is about the integrated capacitated lot sizing problem (CLSP) and maintenance model (Fitouhi & Nourelfath, 2014; Liu, Wang & Peng, 2015b), which is mainly based on the discrete modes of production
Jafari and Makis (2015) developed the joint optimization of EPQ and preventive maintenance (PM) policy for a production facility subject to deterioration and condition monitoring, and they proposed the proportional hazards model to consider condition monitoring information as well as the age of the production facility, the deterioration process is determined by the age and covariate values, the covariate process is modeled as a continuous-time Markov process, this work is extended by Jafari and Makis (2016), they modeled the covariate process as a Semi-Markov decision process
Summary
In modern companies, optimal production planning and optimal maintenance schedule are always studied separately, conflict is generated inevitably since the two activities share the same system. Improper maintenance, or the other harmful effect caused by separated planning about production and maintenance, lots of researches of integrated production and maintenance are developed. Lee and Rung (2000) studied lot-sizing policies in multi-stage serial production systems with the systems prone to failures They concluded that the lot sizes in the unreliable systems could be smaller or larger than those in the classical EPQ model. Chakraborty, Giriand and Chaudhuri (2009) developed integrated production, inventory and maintenance models to study the joint effects of process deterioration, machine breakdown and inspections on the optimal lot-sizing decisions. They concluded that the lot sizes in the unreliable systems could be smaller or larger than those in the classical EPQ model. Giri and Dohi (2004) proposed a net present value approach to determine the EPQ for an unreliable production system over an infinite planning horizon. Sami (2008) considered a system that deteriorates with an increasing failure rate, and proposed a model to determine the optimal number of the production runs and the PM schedule that minimize the long-term average cost. Chakraborty, Giriand and Chaudhuri (2008) presented a EPQ 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 and may break down afterwards. Chakraborty, Giriand and Chaudhuri (2009) developed integrated production, inventory and maintenance models to study the joint effects of process deterioration, machine breakdown and inspections on the optimal lot-sizing decisions. Jafari and Makis (2015) developed the joint optimization of EPQ and PM policy for a production facility subject to deterioration and condition monitoring, and they proposed the proportional hazards model to consider condition monitoring information as well as the age of the production facility, the deterioration process is determined by the age and covariate values, the covariate process is modeled as a continuous-time Markov process, this work is extended by Jafari and Makis (2016), they modeled the covariate process as a Semi-Markov decision process. Bouslah, Gharbi and Pellerin (2016) studied the integrated design of production, continuous sampling inspection and preventive maintenance of a deteriorating production system
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