The Decision of Production Systems with Quality-Contingent Demand and Condition-Based Maintenance

Zhenhua Gao,Hongjun Wang,Hongliang Zhang

doi:10.3390/systems10010020

Abstract

To make a production plan fit with the actual situation better, we focus on the production system with equipment, and design a joint optimization strategy combining the economic production quantity (EPQ) model with condition-based maintenance. In this strategy, different maintenance operations are carried out when the state of the equipment exceeds different thresholds. The numerical relationship between product demand rate and equipment state is established, and the average cost rate is calculated by using the renewal reward theory. An optimization model is proposed, which takes the lowest average cost rate as the objective function with the economic production quantity and condition-based maintenance threshold are taken as the decision variables. An improved genetic algorithm with an elite strategy is used to solve the model. The results shows that the cost of the proposed model is lower and the sensitivity analysis can describe the relationship between the various elements of the production system clearly, understand the system state quickly, and demonstrate the proposed model.

Highlights

Time is progressing, the rising production cost and quality requirements are challenges in the manufacturing industry [1], and it is the key for manufacturers to formulate reasonable production plans
Lu et al [17] studied the influence of product quality on the demand rate of the production systems and introduced it into the perfect preventive maintenance model without considering the deterioration of equipment state
The results showed that the quality of the product impacted the system’s production, and Bouslah [20] gave the numerical relationship of the effect, that is, the relationship between the defective rate and the equipment state

Summary

Introduction

The rising production cost and quality requirements are challenges in the manufacturing industry [1], and it is the key for manufacturers to formulate reasonable production plans. Lu et al [17] studied the influence of product quality on the demand rate of the production systems and introduced it into the perfect preventive maintenance model without considering the deterioration of equipment state. Lin et al [19] considered non-monotonic failure rate and defect rate in the production process and established the production, maintenance and quality integration model of the mass production system with deterioration problems. The proposed model is closer to the actual production process owing to considering the variable demand rate and the deteriorating state. A production model considering the influence of equipment state on defective rate and demand rate is established to ensure the quality of products, improve the reliability of equipment and the profit margin of enterprises. The PM threshold and the economic production quantity are used as decision variables to minimize the manufacturers’ costs

Assumptions

The Integrated Model

Sensitivity Analysis

Findings

Conclusions