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Integrated maintenance, inventory and quality engineering decisions for multi-product systems

Salmasnia Ali, Hafezian Rahil, Maleki Mohammad Reza

Engineering Management in Production and Services

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2022

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Vol. 14, no. 4

94-113

EN

It is essential for manufacturers to consider the interrelation among quality, inventory, and maintenance decisions to detect imperfect quality products, keep the production system in good operating condition, and manage quality and inventory costs. Hence, this paper aims to develop an integrated model of inventory planning, quality engineering, and maintenance scheduling in which the expected total cost per time unit is minimised by determining the sample size, sampling interval, control limit coefficient, along with production cycle time. In this regard, an imperfect multi-product manufacturing system is considered, in which the inventory shortage in satisfying the demand for each product type and the idle time during the production cycle are not allowed. It is assumed that the process starts in an in-control condition where most produced units are conforming. However, due to the occurrence of an assignable cause (AC), the process mean moves to an out-of-control condition in which a significant fraction of non-conforming units is produced. The efficiency of the proposed mathematical model is evaluated by a numerical example, and then the sensitivity of the proposed model to important inputs is analysed. Finally, a comparative study based on the Taguchi design approach is given to confirm the capability of the proposed model to achieve remarkable cost savings.

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Pilot Study on the Application of Employee Scheduling for the Problem of Safety Instrumented System Design and Maintenance Planning for Remotely Located Oil and Gas Facilities

Redutskiy Y.

Engineering Management in Production and Services

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2018

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Vol. 10, no. 4

55--64

EN

The technology of production, transportation, and processing of oil and gas involves various hazardous processes. To mitigate the risk that these processes pose, the technological solutions work closely with the automated control and safety systems. The design and organisation of maintenance for the automated safety instrumented systems (SIS) have a significant bearing on the overall safety of operations in this industry. Over the past few decades, many hydrocarbon resources have been discovered in unconventional environments, such as remote, offshore, and arctic locations. Transportation of engineering personnel to these remote locations and back, and thereby, the organisation of the shift work poses additional challenges for the petroleum sector. Under such circumstances, the workforce-related costs play a considerable role in the overall cost of the technological solution and thereby the decisions regarding the workforce organisation should be addressed in the framework of evaluating and choosing the appropriate safety measures. That is why the research presented in this paper aims to address the lifecycle of the technological solution integrating the problems of SIS design, maintenance planning, and employee scheduling into a single decision-making framework to optimise the set of technical and organisational safety measures inherent in the SIS. The performance and maintenance of the SIS are described with a Markov model of device failures, repairs and technological incidents occurrence. The employee scheduling part of the mathematical model utilises the set-covering formulation of maintenance crews taking particular trips. A black-box optimisation algorithm is used to find reasonable solutions to the integrated problem of engineering design and workforce planning. The decisions include the choices of the components and structures for the safety system, the facility overhaul frequencies, the maintenance personnel size, as well as the schedules of trips and shifts for the crews.

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An integrated model of production scheduling and maintenance planning under imperfect preventive maintenance

Chen X., Xiao L., Zhang X., Xiao W., Li J.

Eksploatacja i Niezawodność

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2015

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Vol. 17, no. 1

70--79

EN

For a successful company, machines are always required to work continuously to make more profit in a certain period. However, machines can be unavailable due to the scheduled maintenance activities or unexpected failures. Hence, a model connected production scheduling with maintenance planning for a production line which is composed of multiple machines is developed. Suppose preventive maintenance is imperfect and cannot renew all the machines. Age reduction factor and hazard rate increase factor are introduced to illustrate the imperfect character. Aperiodic preventive maintenance policy is adopted. Replacement as perfect maintenance could restore the machine “as good as new”. When and whether to perform replacement is based on a cost-time rate function which is defined to judge whether or not the preventive maintenance is economical. The objective of the joint model is to maximize the total profit which is composed of production value, production cost, maintenance cost (including the preventive maintenance cost and replacement cost), and tardiness cost (which is related to the job sequence and maintenance activities). To optimize the objective, immune clonal selection algorithm is utilized. The proposed model is validated by a numerical example.

PL

Aby firma mogła działać z powodzeniem i przynosić większe zyski w danym okresie czasu, zainstalowane w niej maszyny muszą pracować w sposób nieprzerwany. Niestety, z powodu planowych działań obsługowych lub nieoczekiwanych awarii, maszyny są czasami wyłączane z produkcji. Dlatego też w niniejszym artykule opracowano model łączący harmonogramowanie produkcji z planowaniem obsługi technicznej dla linii produkcyjnej złożonej z wielu maszyn. W pracy założono, że konserwacja zapobiegawcza jest niepełna i nie prowadzi do odnowy wszystkich maszyn. Aby zilustrować jej niepełny charakter, wprowadzono pojęcia czynnika redukcji wieku oraz czynnika wzrostu wskaźnika zagrożenia. Przyjęto politykę nieokresowej konserwacji zapobiegawczej. Wymiana jako forma pełnej konserwacji pozwala na przywrócenie maszyny do stanu "fabrycznej nowości". Kiedy i czy należy przeprowadzić wymianę zależy od funkcji wskaźnika kosztu w stosunku do czasu, który pozwala ocenić, czy konserwacja zapobiegawcza jest opłacalna. Model zintegrowany ma na celu maksymalizację całkowitego zysku, który jest wypadkową wartości produkcji, kosztów produkcji, kosztów obsługi (w tym kosztów konserwacji zapobiegawczej oraz kosztów wymiany) i kosztów nieterminowego zakończenia zadania (ang. lateness, związanych z kolejnością wykonywanych zadań i czynności obsługowych). Aby zoptymalizować opisany cel, wykorzystano algorytm odpornościowej selekcji klonalnej Proponowany model zweryfikowano na przykładzie liczbowym.