Risk analysis for lot-sizing and maintenance optimization problem under energy constraint with subcontractor solution

2020 ◽  
Vol 37 (6/7) ◽  
pp. 873-904
Author(s):  
Mohamed Ali Kammoun ◽  
Zied Hajej ◽  
Nidhal Rezg
Keyword(s):  
Risk Analysis ◽  
Preventive Maintenance ◽  
Lot Sizing ◽  
Maintenance Cost ◽  
Lot Size ◽  
Content Type ◽  
Analysis Study ◽  
Dynamic Lot Sizing ◽  
Maintenance Plan ◽  
Maintenance Problem

PurposeThe main contribution of this manuscript is to suggest new approaches in order to deal with dynamic lot-sizing and maintenance problem under aspect energetic and risk analysis. The authors introduce a new maintenance strategy based on the centroid approach to determine a common preventive maintenance plan for all machines to minimize the total maintenance cost. Thereafter, the authors suggest a risk analysis study further to unforeseen disruption of availability machines with the aim of helping the production stakeholders to achieve the obtained forecasting lot-size plan.Design/methodology/approachThe authors tackle the dynamic lot-sizing problem using an efficient hybrid approach based on random exploration and branch and bound method to generate possible solutions. Indeed, the feasible solutions of random exploration method are used as input for branch and bound to determine the near-optimal solution of lot-size plan. In addition, our contribution to the maintenance part is to determine the optimal common maintenance plan for M machines based on a new algorithm called preventive maintenance (PM) periods means.FindingsFirst, the authors have funded the optimal lot-size plan that should satisfy the random demand under service level requirement and energy constraint while minimizing the costs of production and inventory. Indeed, establishing a best lot-size plan is to determine the appropriate number of available machines and manufactured units per period. Second, for risk analysis study, the solution of subcontracting is proposed by specifying a maximum cost of subcontractor in the context of a calling of tenders.Originality/valueFor maintenance problem, the originality consists in regrouping the maintenance plans of M machines into only one plan. This approach lets us to minimize the total maintenance cost and reduces the frequent breaks of production. As a second part, this paper contributed to the development of a new risk analysis study further to unforeseen disruption of availability machines. This risk analysis developed a decision-making system, for production stakeholders, in order to achieve the forecasting lot-size plan and keeps its profitability, by specifying the unit cost threshold of subcontractor in the context of a calling of tender.

A Joint Model of Production and Preventive Maintenance Plan

2010 ◽  
Vol 156-157 ◽  
pp. 18-23
Author(s):  
Zhi Qiang Lu ◽  
Yue Jun Zhang
Keyword(s):  
System Reliability ◽  
Preventive Maintenance ◽  
Lot Sizing ◽  
Threshold Value ◽  
Joint Model ◽  
Production Plan ◽  
Lot Sizing Problem ◽  
Capacitated Lot Sizing ◽  
The Difference ◽  
Maintenance Plan

We integrated run-based preventive maintenance (PM) into the production plan at the tactical level. The production plan was based on the single level capacitated lot-sizing problem (CLSP). We assumed the system reliability should be kept above certain threshold value to ensure the feasibility of the production plan; the reliability would be affected only by system running. Thus, PM would be triggered by the reliability requirement and the accumulated running time. We established this relationship as a nonlinear integer constraint in the joint model. We also proposed a branch and bound algorithm using CPLEX to solve the model. Finally, a numerical example was given to illustrate the difference between run-based and time-based PM.

Polynomial-Time Solvability of Dynamic Lot Size Problems

2016 ◽  
Vol 33 (03) ◽  
pp. 1650018
Author(s):  
Chung-Lun Li ◽  
Qingying Li
Keyword(s):  
Polynomial Time ◽  
Lot Sizing ◽  
Sufficient Conditions ◽  
Quantity Discounts ◽  
Lot Size ◽  
Minimum Order ◽  
Cost Structures ◽  
Minimum Order Quantity ◽  
Dynamic Lot Sizing ◽  
Dynamic Lot Size

There has been a lot of research on dynamic lot sizing problems with different nonlinear cost structures due to capacitated production, minimum order quantity requirements, availability of quantity discounts, etc. Developing optimal solutions efficiently for dynamic lot sizing models with nonlinear cost functions is a challenging topic. In this paper, we present a set of sufficient conditions such that if a single-item dynamic lot sizing problem satisfies these conditions, then the existence of a polynomial-time solution method for the problem is guaranteed. Several examples are presented to demonstrate the use of these sufficient conditions.

scholarly journals A Simulation Model for Machine Efficiency Improvement Using Reliability Centered Maintenance: Case Study of Semiconductor Factory

2014 ◽  
Vol 2014 ◽  
pp. 1-9 ◽  
Author(s):  
Srisawat Supsomboon ◽  
Kanthapong Hongthanapach
Keyword(s):  
Preventive Maintenance ◽  
Selection Process ◽  
Reliability Estimation ◽  
Maintenance Cost ◽  
Risk Level ◽  
Test Machine ◽  
Optimization Approach ◽  
Efficiency Improvement ◽  
Reliability Centered Maintenance ◽  
Maintenance Plan

The purpose of this study was to increase the quality of product by focusing on the machine efficiency improvement. The principle of the reliability centered maintenance (RCM) was applied to increase the machine reliability. The objective was to create preventive maintenance plan under reliability centered maintenance method and to reduce defects. The study target was set to reduce the Lead PPM for a test machine by simulating the proposed preventive maintenance plan. The simulation optimization approach based on evolutionary algorithms was employed for the preventive maintenance technique selection process to select the PM interval that gave the best total cost and Lead PPM values. The research methodology includes procedures such as following the priority of critical components in test machine, analyzing the damage and risk level by using Failure Mode and Effects Analysis (FMEA), calculating the suitable replacement period through reliability estimation, and optimizing the preventive maintenance plan. From the result of the study it is shown that the Lead PPM of test machine can be reduced. The cost of preventive maintenance, cost of good product, and cost of lost product were decreased.

Maintenance scheduling based on PROMETHEE method in conjunction with group technology philosophy

2018 ◽  
Vol 35 (7) ◽  
pp. 1423-1444 ◽  
Author(s):  
Abdelhakim Abdelhadi
Keyword(s):  
Preventive Maintenance ◽  
Group Technology ◽  
Spare Parts ◽  
Strategic Decision ◽  
Maintenance Cost ◽  
Manufacturing Strategy ◽  
Content Type ◽  
Clustering Problem ◽  
Promethee Method ◽  
The Impact

Purpose The purpose of this paper is to implement a strategic decision-making framework by selecting clusters of maintainable machines and scheduling their maintenance as part of a company’s manufacturing strategy. Design/methodology/approach Multi-criteria clustering problem in conjunction with the application of a group technology is used to establish clusters of maintainable machines based on their need for maintenance according to the type of failures they can encounter. Findings Using the concept of group technology in conducting preventive maintenance will result in the grouping of machines according to the impact of a failure based on the criteria specified by the decision makers. Accordingly, it will facilitate the process of executing the maintenance itself by ordering spare parts and informing the maintenance personnel which will lead to minimize the maintenance cost. Originality/value The results presented in this paper are reliable, objective may be used to minimize the total cost of conducting preventive maintenance in a manufacturing environment.

Optimal production lot sizing for an imperfect manufacturing system with machine breakdown and emergency maintenance policy

Kybernetes ◽  
2019 ◽  
Vol 49 (5) ◽  
pp. 1533-1560
Author(s):  
Xinfeng Lai ◽  
Zhixiang Chen ◽  
Bhaba R. Sarker
Keyword(s):  
Manufacturing System ◽  
Lot Sizing ◽  
Lot Size ◽  
Maintenance Policy ◽  
Managerial Implication ◽  
Optimal Production ◽  
Expected Cost ◽  
Content Type ◽  
Machine Breakdown ◽  
Production Lot Size

Purpose The purpose of this paper is to study a production lot sizing problem with consideration of imperfect manufacturing and emergency maintenance policy, providing managerial implication for practitioners. Design/methodology/approach In this study, the authors introduce two models, where in Model I, shortages are not allowed and repair times are negligible. In Model II, shortages are allowed and are partially backlogged, and repair times are assumed to be exponentially distributed, algorithm is developed to solve the models, numerical examples were demonstrated the applications. Findings Results show that in the Model I, demand rate is the most significant parameter affecting the average expected cost, whereas the time needed to breakdown after machine shift is the most significant factor affecting the production lot size. Therefore, reduction in the time needed to breakdown after machine shift would be helpful for determining an appropriate production lot size in Model I. In Model II, repair time parameter is the most significant factor affecting the average expected cost. Reducing the value of machine shift parameter would be helpful for determining an adequate production lot size and reducing decision risk. Practical implications This paper can provide important reference value for practitioners with managerial implication of how to effectively maintain equipment, i.e. how to make product lot size considering the influence of the maintenance policy. Originality/value From the aspect of academia, this paper provides a solution to the optimal production lot sizing decision for an imperfect manufacturing system with consideration of machine breakdown and emergency maintenance, which is a supplement to imperfect EMQ model.

scholarly journals A heuristic solution of multi-item single level capacitated dynamic lot-sizing problem

1970 ◽  
Vol 38 ◽  
pp. 1-7 ◽  
Author(s):  
Sultana Parveen ◽  
AFM Anwarul Haque
Keyword(s):  
Lot Sizing ◽  
Research Work ◽  
Optimal Solution ◽  
Point Of View ◽  
Lot Size ◽  
Heuristic Solution ◽  
Single Level ◽  
Solution Algorithms ◽  
Lot Sizing Problem ◽  
Dynamic Lot Sizing

The multi-item single level capacitated dynamic lot-sizing problem consists of scheduling N items over a horizon of T periods. The objective is to minimize the sum of setup and inventory holding costs over the horizon subject to a constraint on total capacity in each period. No backlogging is allowed. Only one machine is available with a fixed capacity in each period. In case of a single item production, an optimal solution algorithm exists. But for multi-item problems, optimal solution algorithms are not available. It has been proved that even the two-item problem with constant capacity is NP (nondeterministic polynomial)-hard. That is, it is in a class of problems that are extremely difficult to solve in a reasonable amount of time. This has called for searching good heuristic solutions. For a multi-item problem, it would be more realistic to consider an upper limit on the lot-size per setup for each item and this could be a very important parameter from practical point of view. The current research work has been directed toward the development of a model for multi-item problem considering this parameter. Based on the model a program has been executed and feasible solutions have been obtained. Keywords: Heuristics, inventory, lot-sizing, multi-item, scheduling.DOI: 10.3329/jme.v38i0.893 Journal of Mechanical Engineering Vol.38 Dec. 2007 pp.1-7

An operating environment-based preventive maintenance decision model

2019 ◽  
Vol 26 (4) ◽  
pp. 592-610
Author(s):  
Aiping Jiang ◽  
Qingxia Li ◽  
Jinyi Yan ◽  
Leqing Huang ◽  
Haining Wu
Keyword(s):  
Reliability Analysis ◽  
Preventive Maintenance ◽  
Decision Model ◽  
Maintenance Cost ◽  
Redundant System ◽  
Content Type ◽  
Multiple Components ◽  
Safety And Reliability ◽  
Optimal Maintenance ◽  
The Cost

Purpose The purpose of this paper is to focus on finding the optimal maintenance interval and the minimum maintenance cost for redundant system, considering environment factors. Design/methodology/approach The authors propose a decision model with environment-based preventive maintenance for the repairable redundant system. Referring to the k-out-of-n model and Proportional Hazard Model, the reliability analysis is completed for the redundant system affected by internal and external issues. Meanwhile, the maintenance cost for the redundant system is divided into two categories: the fixed maintenance cost involving whole system replacement at the time of system failure, and the cost to replace failure components when the system still functions. Findings Upon the required reliability analysis, an optimal maintenance interval that minimizes the average maintenance cost per unit time is identified. The simulation results indicate that the optimal maintenance interval with consideration of environmental factors is significantly shorter than that without consideration of these factors, with the maintenance cost increase within 10 percent. Practical implications The redundant systems have widely been used in industries including the aero craft control system and warship power system. The model could be applied in the more real case considering the types of components and the operation environment, and help production managers better maintain machines by increasing the safety and reliability of the redundant model with the more frequent inspection. Originality/value Previous research of redundant system always focuses on internal degradation, while ignoring the reliability analysis for a redundant system with various multiple components under the influence of environment. However, this work could fill the theoretical gap, i.e. simultaneously consider both environmental and internal factors for a redundant system with non-homogeneous components. Meanwhile, the proposed superior model increases the reliability and safety of the k-out-of-n model with reasonable cost. Production managers could benefit a lot from this as well.

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