A mixed-integer linear programming model for integrated production and preventive maintenance scheduling in the capital goods industry

Abstract

Newcastle University ePrints | eprint.ncl.ac.uk Chansombat S, Pongcharoen P, Hicks C. A mixed-integer linear programming model for integrated production and preventive maintenance scheduling in the capital goods industry. AbstractThe scheduling literature is extensive, but much of this work is theoretical and does not capture the complexity of real world systems. Capital goods companies produce products with deep and complex product structures, each of which requires the coordination of jobbing, batch, flow and assembly processes. Many components require numerous operations on multiple machines. Integrated scheduling problems simultaneously consider two or more simultaneous decisions. Previous production scheduling research in the capital goods industry has neglected maintenance scheduling and used metaheuristics with stochastic search that cannot guarantee an optimal solution. This paper presents a novel mixed integer linear programming (MILP) model for simultaneously solving the integrated production and preventive maintenance scheduling problem in the capital goods industry, which was tested using data from a collaborating company. The objective was to minimise total costs including: tardiness and earliness penalty costs; component and assembly holding costs; preventive maintenance costs; and setup, production, transfer and production idle time costs. Thus, the objective function and problem formulation were more extensive than previous research. The tool was successfully tested using data obtained from a collaborating company. It was found that the company's total cost could be reduced by up to 63.5%.

A Novel Integer Linear Programming Formulation for Job-Shop Scheduling Problems

“…To linearize such a function, one additional decision variable is required, and the number of additional constraints equals the number of non-zero segments. For our 3segment function (16), the number of non-zero segments is two. Therefore, the numbers of additional decision variables and constraints required is equal to those required by the absolutevalue function.…”

Proposed Procedure for Optimal Maintenance Scheduling Under Emergent Failures

“…Bertolini et al (2019) conducted comparison of new metaheuristics, for the solution of an integrated jobs-maintenance scheduling problem. Chansombat et al (2019) proposed a mixed-integer linear programming model for integrated production and preventive maintenance scheduling in the capital goods industry. Miyata et al (2019a) incorporated preventive maintenance into the m-machine no-wait flow-shop scheduling problem with total flow-time minimization.…”

“…While, emergent failures, which happen due to the occurrence of emergency events need immediate repairs due to avoid failure consequences; severity or production losses (Seif et al, 2018;Tonke & Grunow, 2018). In previous literature, maintenance scheduling problem has been extensively studied (Irawan et al, 2017;Kiefer et al, 2018;Chansombat et al, 2019). However, maintenance engineers are still challenged to handle repairs scheduling of emergent failures.…”

A Multi-Objective Modeling Approach for Integrated Manufacturing and Preventive Maintenance Planning

“…A proactive approach to solve integrated production scheduling and maintenance planning problem in a multi-component flow shop application is developed by Cui et al (2018) in order to optimize the bi-objective of quality robustness and solution robustness with failure uncertainty. In another study, Chansombat et al (2018) presents a novel mixed integer linear programming model for simultaneously solving the integrated problem for a multicomponent production system in the capital goods industry. Najid et al (2011) addressed the problem of finding optimal production lot sizes of various items by taking into account demand shortage and the reliability of the production line.…”