Preventive maintenance and silica exposure limits integrated in the production planning of a granite processing unit

Abstract

PurposeThis paper studies the integration of production and maintenance planning for an unreliable production system subject to gradual deterioration. The goal of this planning is to optimize production and maintenance while reducing workers' exposure to silica dust. The objective will therefore be to offer manufacturers a production strategy that minimizes the total cost of production while considering the health of employees.Design/methodology/approachAdequate prevention methods are determined and integrated into the granite transformation production system, which evolves in a stochastic environment. With the failure rate of the dust reduction unit being a function of its degradation state, the authors solve the optimization problem using stochastic dynamic programming in the context of nonhomogeneous Markov chain.FindingsThe resulting planning strategy shows that one can manage stock optimally while ensuring a healthy environment for workers. It ensures that crystalline silica prevention equipment is available and effective and defines the production rate according to a critical threshold, which is a function of the age of the dust reduction unit.Research limitations/implicationsThis article illustrates that it is possible to integrate silica dust reduction measures into production planning while remaining optimal and ensuring the health of operators. In the present study, the machined granite was assumed to be a natural granite, and production takes place in a closed environment.Originality/valueThe originality of this work lies in its development of an optimal joint production and maintenance strategy, which considers limits of exposure to crystalline silica. An optimal production and maintenance control policy considering employees' health is therefore proposed.