Abstract
A smart production system is essential to produce complex products under the consumption of efficient energy. The main ramification of controllable production rate, amount of production size, and safety stocks is simultaneously optimized under proper utilization of energy within a smart production system with a random breakdown of spare parts. Due to the random breakdown, a greater amount of energy may be used. For this purpose, this study is concerned about the optimum safety stock level under the exact amount of energy utilization. For random breakdown, there are three cases as production inventory meets the demand without utilization of the safety stock, with using of the safety stock, and consumed the total safety stock amount and facing shortages. After the random breakdown time, the smart production system may move to an out-of-control state and may produce defective items, where the production rate of defective items is a random variable, which follows an exponential distribution. The total cost is highly nonlinear and cannot be solved by any classical optimization technique. A mathematical optimization tool is utilized to test the model. Numerical study proves that the effect of energy plays an important role for the smart manufacturing system even though random breakdowns are there. it is found that the controllable production rate under the effect of the optimum energy consumption really effects significantly in the minimization cost. It saves cost regarding the corrective and preventive maintenance cost. The amount of safety stock can have more support under the effect of optimum energy utilization. The energy can be replaced by the solar energy.
Highlights
The main development in the production sector is the inspection of smart manufacturing within the production context
It is a smart production system, random breakdown and defective production exists under controllable energy consumption and production rate, how safety stock can be maintained within the production with the minimum cost
This study reveals a strong recommendation how the industry will manage the situation of the breakdown within the framework of smart production system, where generally breakdown is not expected
Summary
The main development in the production sector is the inspection of smart manufacturing within the production context. A two-echelon supply chain model with quality improvement and setup cost reduction in a tradition production system was considered by Sarkar et al [31], but production rate is constant though it moves to out-of-control state. There is a research gap in the direction of smart production direction with random breakdown under the proper application of corrective and preventive maintenance where the main task is to control used energy within the smart production system. This proposed model has solved this research gap for this matter. Problem definition, assumptions and notation are given
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