Analysis of long flow lines with quality and operational failures

Kim, Jongyoon; Gershwin, Stanley B.

doi:10.1080/07408170701558607

Cited by 68 publications

(25 citation statements)

References 14 publications

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“…We can considerably simplify Equation (16), noting that the second integral in the interval , ∞ is the value function , , a , and reducing the discounted rate. Moreover assuming that the value function is differentiable allows us to apply its full derivative.…”

Section: Deterioration Modelingmentioning

confidence: 99%

“…Another important aspect is the fact that deterioration also has an effect on the quality of the parts produced. A number of authors have proposed the link between deterioration and quality, such as Kim and Gershwin (2008) who suggested that in modeling the wear of the machine, it can also be used to represent different quality yields. Additionally, Colledani and Tolio (2011) claimed that the existence of a degrading process in production systems may have a continuous deterioration on the quality of parts.…”

Section: Deterioration Modelingmentioning

confidence: 99%

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Joint control of production, overhaul, and preventive maintenance for a production system subject to quality and reliability deteriorations

Rivera-Gómez

Gharbi

Kenné

2013

Int J Adv Manuf Technol

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This research investigates the case of an unreliable manufacturing system subject to quality and reliability deterioration. In particular, we conjecture that the deterioration of the system leads to a continuous increase in the intensity of failures and a decrease on the quality of the parts produced. As such, deterioration implies a twofold effect on the manufacturing system. When the machine fails, minimal repair is conducted, leaving the machine at the same level of deterioration before failure. Hence, the quality of the parts produced and the failure intensity remain unchanged with this repair. Meanwhile, an overhaul refers to a perfect repair that completely restores the quality of the parts and the failure intensity of the machine. This option completely counters all the effects of the deterioration. Preventive maintenance may also be conducted, but it reduces the level of deterioration only partially, improving the quality of the units produced and the failure intensity just in part. These set of characteristics yield to the formulation of a new control model that simultaneously determines the optimal production plan, the overhaul and preventive maintenance strategies. Such a joint control policy minimizes the total cost including the inventory holding, backlog, overhaul, preventive maintenance and defectives costs over an infinite planning horizon. Since the dynamics of the system change as a function of the level of deterioration, it is necessary to use its history for a proper formulation; therefore a Semi-Markov decision process is used. Numerical methods are applied to determine the control policy and numerical examples are conducted as illustrations. An extensive sensitivity analysis is presented in order to confirm the structure of the control policy obtained and examine the effect of several parameters.

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Section: Deterioration Modelingmentioning

confidence: 99%

Section: Deterioration Modelingmentioning

confidence: 99%

Joint control of production, overhaul, and preventive maintenance for a production system subject to quality and reliability deteriorations

Rivera-Gómez

Gharbi

Kenné

2013

Int J Adv Manuf Technol

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“…In this respect we find that some authors relate the deterioration of the machine with the quality of the parts produced. For example Kim and Gershwin (2008), proposed a general model that represents the wear of the machine and that also indicates different quality levels, implying a deterioration of quality. In the same direction Colledani and Tolio (2011) suggest that the degrading process of the machine has a continuous deterioration on the parts' quality.…”

Section: Deteriorating Systemsmentioning

confidence: 99%

Production and quality control policies for deteriorating manufacturing system

Rivera-Gómez¹,

Gharbi²,

Kenné³

2013

International Journal of Production Research

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In this paper, a novel model for a deteriorating manufacturing system is analyzed, considering repairs and overhauls of random durations. The machine manufactures one product and the model is further complicated because the quality of the parts' produced deteriorates according to the wear of the machine and human interventions. When a breakdown occurs, either a repair or an overhaul is performed. The machine is restored to as-good-as-new conditions if the overhaul is selected, and conversely, its condition deteriorates following repairs. Multiple operational states are considered to define an aging process. The decision variables of the model are the production rate and the repair/overhaul switching strategy. This paper provides new insights to this research area by considering the simultaneous production and repair/overhaul control policy under the effect of deteriorations. The optimal decision policy minimizes the total incurred cost comprising the inventory, backlog, repair and overhaul costs over an infinite planning horizon. Our paper differs from other research projects in its consideration of the machine's history, defined by the number of repairs and multiple operational states. A numerical example is given to illustrate the proposed approach and a sensitivity analysis has been conducted to confirm the structure of the obtained control policies.

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“…In this study, we collect and analyze data for a steady state profit which as much as possible approximates that defined by the objective function given by equation (4).…”

Section: Experimental Designmentioning

confidence: 99%

“…Based on the assumption that a machine will continue to produce defective parts until its operation is corrected, the main objective of their work is to study the interaction of quality and productivity. More recently, Kim and Gershwin [4] have extended this model and proposed approximation methods for the analysis of production line performance. Although these models represent a pioneering contribution, we observe that possible modeling difficulties can occur in that parts production is modeled as fluid, yet quality remains attached to discrete parts.…”

Section: Introductionmentioning

confidence: 99%

Integrated product specifications and productivity decision making in unreliable manufacturing systems

Hajji

Mhada

Gharbi

et al. 2011

International Journal of Production Economics

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This paper considers joint production control and product specifications decision making in a failure prone manufacturing system. This is with the knowledge that tight process specifications, while leading to a product of more reliable quality and higher market value, are at the same time associated with higher levels of non conforming parts, a higher rate of parts rejection and thus a lowering of overall plant productivity. The decision making is further complicated by the lack of reliability of the production process which imposes that an adequate, also to be designed, level of inventory of finished parts be maintained. The overall optimal decision policy is defined here as one that maximizes the long term average per unit time profit of a combined measure of quality and quantity dependent sales revenue, minus inventory and backlog costs, in the presence of random plant failures and random repair durations. Policy optimization is achieved via a revisited model of the BieleckiKumar theory for Markovian machines and a simulation and experimental design based methodology for the more general cases.

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Analysis of long flow lines with quality and operational failures

Cited by 68 publications

References 14 publications

Joint control of production, overhaul, and preventive maintenance for a production system subject to quality and reliability deteriorations

Joint control of production, overhaul, and preventive maintenance for a production system subject to quality and reliability deteriorations

Production and quality control policies for deteriorating manufacturing system

Integrated product specifications and productivity decision making in unreliable manufacturing systems

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