This study is on the integrated planning problem of maintenance and production within the frame work of a system subject to periodic preventive replacements with minimal repairs in case of unplanned failures. A model was developed using the overall cost by considering the interdependence between the maintenance plan and the production schedule. The overall cost contains two parts: the costs of launching a product, production, storage and breaking on the demand and the preventive and corrective maintenance costs for multi-periods and multi-products systems. The purpose of this integration is to find simultaneously the optimal cycle T at which the preventive maintenance takes place and the optimal values of lot-size by adding the setup time constraint. Using the mixed integer linear programming these optimal values minimize the total cost over a finite horizon. The results show that the proposed model performs quite well and opens new research direction for future improvements.
This article discusses the issue of integrated planning of maintenance activities and production operations at the tactical level for multi-line systems with separate resources and introducing the breaking on demand constraint and that of setup time. The maintenance policy offers preventive replacements in the beginning of each cycle and minimal repairs in case of random failure. The model defined an objective function that reduces the overall cost and can simultaneously determine the optimal production plan (producing, lunching, storing and breaking costs) and the moment of replacement. The resolution is made with the mixed integer linear solver CPLEX. Then we provide a numerical example to illustrate the results and represent the economic gap between the separate and integrated planning.
In spite of the interdependence between them, production and maintenance planning decisions are generally studied and used independently in the majority of the manufacturing systems. Our contribution is summarized to obtain a maintenance policy including preventive replacement in each maintenance cycle and minimal repair in case of unplanned failure, and on the other side, for a set of products and in each period, specify the quantity to be produced and when is the production set up, also the stock and the breaking on demand level, so that to minimize the total cost. The purpose of the research was aimed at achieving the optimization of an integrated planning of preventive maintenance and production in a multi-period, multiproduct, and single-line production system. To achieve this purpose, our model is configured as a mixed integer linear programming and solved by IBM ILOG CPLEX OPL studio 12.6 (USA), and we propose our own genetic algorithms (GAs) using Python solver with respect to resolution time and the quality of results. Then, to find the performance of the model and the usefulness of the proposed resolution method, a numerical example is considered to produce two products for a finite horizon with 11 periods. The results of the analysis show that this GA provides a new tool for the integrated planning in the industrial sector. These results reflect the experiences of single-line system and further studies are needed for generalizability in the multiline cases, also we will compare the proposed GA with other evolutionary algorithms.
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