Optimal maintenance of a series production system with two multi-component subsystems and an intermediate buffer

• Autorzy: Zhou Y. , Zhang Z.

Warianty tytułu

PL

Optymalna strategia utrzymania ruchu dla seryjnego systemu produkcji złożonego z dwóch podsystemów wieloskładnikowych oraz buforu pośredniego

• Języki publikacji: EN

Abstrakty

EN

Intermediate buffers often exist in practical production systems to reduce the influence of the breakdown and maintenance ef subsystems on system production. At the same time, the effects of intermediate buffers also make the degradation process of the system more difficult to model. Some existing papers investigate the performance evaluation and maintenance optimisation of a production system with intermediate buffers under a predetermined maintenance strategy structure. However, only few papers pay attention to the property of the optimal maintenance strategy structure. This paper develops a method based on the Markov decision process to identify the optimal maintenance strategy for a series-parallel system with two multi-component subsystems and an intermediate buffer. The structure of the obtained optimal maintenance strategy is analysed, which shows that the optimal strategy structure cannot be modelled by a limited number of parameters. However, some useful properties of the strategy structure are obtained, which can simplify the maintenance optimisation. Another interesting finding is that a large buffer capacity cannot always bring about high average revenue even through the cost of holding an item in the buffer is much smaller than the production revenue per item.

PL

W systemach produkcyjnych często stosuje się bufory pośrednie w celu zmniejszenia wpływu awarii i konserwacji podsystemów na system produkcji. Jednocześnie, oddziaływanie buforów pośrednich utrudnia modelowanie procesu degradacji systemu. Istnieją badania dotyczące oceny funkcjonowania i optymalizacji utrzymania systemów produkcyjnych wykorzystujących bufory pośrednie przy założeniu wcześniej określonej struktury strategii utrzymania ruchy. Jednak tylko nieliczne prace zwracają uwagę na własności optymalnej struktury strategii utrzymania ruchu. W przedstawionej pracy opracowano opartą na procesie decyzyjnym Markowa metodę określania optymalnej strategii utrzymania ruchu dla układu szeregowo-równoległego z dwoma podsystemami wieloskładnikowymi oraz buforem pośrednim. Przeanalizowano strukturę otrzymanej optymalnej strategii utrzymania i wykazano, że struktury takiej nie można zamodelować przy użyciu ograniczonej liczby parametrów. Jednak odkryto pewne przydatne właściwości struktury strategii, które mogą ułatwić optymalizację utrzymania ruchu. Innym interesującym odkryciem było to, że duża pojemność bufora nie zawsze daje wysoką średnią przychodów mimo iż koszty przechowywania obiektu w buforze są znacznie mniejsze niż przychody z produkcji w przeliczeniu na jeden obiekt.

Słowa kluczowe

EN

series-parallel systems; intermediate buffers; Markov decision process; policy iteration; generalized minimum residual method

PL

układ szeregowo-równoległy; bufor pośredni; proces decyzyjny Markowa; iteracja strategii; uogólniona metoda najmniejszego residuum

• Wydawca: Polskie Naukowo-Techniczne Towarzystwo Eksploatacyjne
• Czasopismo: Eksploatacja i Niezawodność
• Rocznik: 2015
• Tom: Vol. 17, no. 2
• Strony: 314--325
• Opis fizyczny: Bibliogr. 25 poz., rys., tab.

Twórcy

autor

Zhou Y.

• School of Mechanical Engineering Southeast University Nanjing, China, 211189 Jiangsu Key Laboratory of Large Engineering Equipment Detection and Control Xuzhou Institute of Technology Xuzhou, China, 221018

autor

Zhang Z.

• School of Mechanical Engineering Southeast University Nanjing, China, 211189

Bibliografia

• 1. Alexandros, D.C. and Chrissoleon, P.T. Exact analysis of a two-workstation one-buffer flow line with parallel unreliable machines. European Journal of Operational Research 2009;197(2):572-580, http://dx.doi.org/10.1016/j.ejor.2008.07.004.
• 2. Arab, A., Ismail, N. and Lee, L.S. Maintenance scheduling incorporating dynamics of production system and real-time information from workstations. Journal of Intelligent Manufacturing 2013;24(4):695-705, http://dx.doi.org/10.1007/s10845-011-0616-3.
• 3. Barrett, R., Berry, M., Chan, T.F. and Demmel, J. Templates for the Solution of Linear Systems: Building Blocks for Iterative Methods.Philadelphia: SIAM; 1994, http://dx.doi.org/10.1137/1.9781611971538.
• 4. Belmansour, A.-T. and Nourelfath, M. An aggregation method for performance evaluation of a tandem homogenous production line with machines having multiple failure modes. Reliability Engineering & System Safety 2010;95(11):1193-1201, http://dx.doi.org/10.1016/j.ress.2010.05.002.
• 5. Dallery, Y., David, R. and Xie, X.L. Approximate analysis of transfer lines with unreliable machines and finite buffers. Automatic Control, IEEE Transactions on 1989;34(9):943-953, http://dx.doi.org/10.1109/9.35807.
• 6. Dehayem Nodem, F.I., Kenné, J.P. and Gharbi, A. Simultaneous control of production, repair/replacement and preventive maintenance of deteriorating manufacturing systems. International Journal of Production Economics 2011;134(1):271-282, http://dx.doi.org/10.1016/j.ijpe.2011.07.011.
• 7. Dimitrakos, T.D. and Kyriakidis, E.G. A semi-Markov decision algorithm for the maintenance of a production system with buffer capacity and continuous repair times. International Journal of Production Economics 2008;111(2):752-762, http://dx.doi.org/10.1016/j.ijpe.2007.03.010.
• 8. Gu, X., Lee, S., Liang, X., Garcellano, M., Diederichs, M. and Ni, J. Hidden maintenance opportunities in discrete and complex production lines. Expert Systems with Applications 2013;40(11):4353-4361, http://dx.doi.org/10.1016/j.eswa.2013.01.016.
• 9. Hamada, M., Martz, H.F., Berg, E.C. and Koehler, A.J. Optimizing the product-based availability of a buffered industrial process. Reliability Engineering & System Safety 2006;91(9):1039-1048, http://dx.doi.org/10.1016/j.ress.2005.11.059.
• 10. Karamatsoukis, C.C. and Kyriakidis, E.G. Optimal maintenance of two stochastically deteriorating machines with an intermediate buffer. European Journal of Operational Research 2010;207(1):297-308, http://dx.doi.org/10.1016/j.ejor.2010.04.022.
• 11. Kyriakidis, E.G. and Dimitrakos, T.D. Optimal preventive maintenance of a production system with an intermediate buffer. European Journal of Operational Research 2006;168(1):86-99, http://dx.doi.org/10.1016/j.ejor.2004.01.052.
• 12. Levantesi, R., Matta, A. and Tolio, T. Performance evaluation of continuous production lines with machines having different processing times and multiple failure modes. Performance Evaluation 2003;51(2–4):247-268, http://dx.doi.org/10.1016/S0166-5316(02)00098-6.
• 13. Liu, J., Yang, S., Wu, A. and Hu, S.J. Multi-state throughput analysis of a two-stage manufacturing system with parallel unreliable machines and a finite buffer. European Journal of Operational Research 2012;219(2):296-304, http://dx.doi.org/10.1016/j.ejor.2011.12.025.
• 14. Maillart, L.M. Maintenance Policies for Systems with Condition Monitoring and Obvious Failures. IIE Transactions 2006; 38463-475.
• 15. Moustafa, M.S., Maksoud, E.Y.A. and Sadek, S. Optimal major and minimal maintenance policies for deteriorating systems. Reliability Engineering & System Safety 2004; 83(3): 363-368, http://dx.doi.org/10.1016/j.ress.2003.10.011.
• 16. Murino, T., Romano, E. and Zoppoli, P. Maintenance policies and buffer sizing: an optimization model. WSEAS TRANSACTIONS on BUSINESS and ECONOMICS 2009; 6(1): 21-30.
• 17. Ribeiro, M.A., Silveira, J.L. and Qassim, R.Y. Joint optimisation of maintenance and buffer size in a manufacturing system. European Journal of Operational Research 2007; 176(1): 405-413, http://dx.doi.org/10.1016/j.ejor.2005.08.007.
• 18. Saad, Y. Preconditioning Techniques. Iterative Methods for Sparse Linear Systems: PWS Publishing Company; 1996.
• 19. Tan, B. and Gershwin, S. Modelling and analysis of Markovian continuous flow systems with a finite buffer. Annals of Operations Research 2011; 182(1): 5-30, http://dx.doi.org/10.1007/s10479-009-0612-6.
• 20. Tan, B. and Gershwin, S.B. Analysis of a general Markovian two-stage continuous-flow production system with a finite buffer. International Journal of Production Economics 2009;120(2):327-339, http://dx.doi.org/10.1016/j.ijpe.2008.05.022.
• 21. Terracol, C. and David, R. An aggregation method for performance evaluation of transfer lines with unreliable machines and finite buffers. Robotics and Automation. Proceedings. 1987 IEEE International Conference on1987: 1333-1338.
• 22. Tijms, H.C. and van der Duyn Schouten, F.A. A Markov decision algorithm for optimal inspections and revisions in a maintenance system with partial information. European Journal of Operational Research 1985;21(2):245-253, http://dx.doi.org/10.1016/0377-2217(85)90036-0.
• 23. Zequeira, R.I., Valdes, J.E. and Berenguer, C. Optimal buffer inventory and opportunistic preventive maintenance under random production capacity availability. International Journal of Production Economics 2008; 111(2):686-696, http://dx.doi.org/10.1016/j.ijpe.2007.02.037.
• 24. Zhang, Z., Zhou, Y., Sun, Y. and Ma, L. Condition-based Maintenance Optimisation without a Predetermined Strategy Structure for a Twocomponent Series System. Eksploatacja i Niezawodnosc – Maintenance and Reliability 2012; 14(2):120–129.
• 25. Zhou, X., Lu, Z. and Xi, L. A dynamic opportunistic preventive maintenance policy for multi-unit series systems with intermediate buffers. Int. J. Industrial and Systems Engineering 2010;6(3): 276-288, http://dx.doi.org/10.1504/IJISE.2010.035012.