Joint design of control chart, production and maintenance policy for unreliable manufacturing systems

Abstract

<jats:sec><jats:title content-type="abstract-subheading">Purpose</jats:title><jats:p>The purpose of this study is to develop a joint production, maintenance and quality control strategy involving a periodic preventive maintenance policy.</jats:p></jats:sec><jats:sec><jats:title content-type="abstract-subheading">Design/methodology/approach</jats:title><jats:p>The proposed integrated policy is defined and modeled mathematically.</jats:p></jats:sec><jats:sec><jats:title content-type="abstract-subheading">Findings</jats:title><jats:p>The paper focuses on finding simultaneously the optimal values of the preventive maintenance period, the buffer stock size, the sample size, the sampling interval and the control chart limits, such that the expected total cost per time unit is minimized.</jats:p></jats:sec><jats:sec><jats:title content-type="abstract-subheading">Practical implications</jats:title><jats:p>The paper attempts to integrate in a single model the three main aspects of any manufacturing system: production, maintenance and quality. The considered system consists of one machine subject to a degradation process that directly affects the quality of products. The process and product quality control is carried out using an “<jats:italic>x-bar</jats:italic>” control chart. In the proposed model, a preventive maintenance action is performed every <jats:inline-formula><m:math xmlns:m="http://www.w3.org/1998/Math/MathML"><m:mi>α</m:mi></m:math><jats:inline-graphic xmlns:xlink="http://www.w3.org/1999/xlink" xlink:href="JQME-01-2020-0006014.tif" /></jats:inline-formula> inspections of product quality in order to reduce the shift rate to the “out-of-control” state. A corrective maintenance action is undertaken once the control limits are exceeded. In order to palliate perturbations caused by the stopping of the machine to undergo maintenance actions, a buffer stock is built up to ensure the continuous supply of the subsequent machine. The main goal of this work is to develop a model that captures the underlying link between the preventive maintenance policy, the buffer stock size and the parameters of an “<jats:italic>x-bar</jats:italic>” control chart used to control the quality of the product. Numerical experiments and a study of the effects of the input parameters variation on the obtained results are performed.</jats:p></jats:sec><jats:sec><jats:title content-type="abstract-subheading">Originality/value</jats:title><jats:p>The existing models that simultaneously consider maintenance, inventory and control charts consist of a condition-based maintenance (CBM) policy. Periodic preventive maintenance (PM) has not been considered in such models. The proposed integrated model is original, in that it links production through buffer stocks, quality through a control chart and maintenance through periodic preventive maintenance (different practical settings and modeling approach than when CBM is used). Hence, this paper addresses practical situations where, for economic or technical reasons, only systematic periodic preventive maintenance is possible.</jats:p></jats:sec>

Big data supply chain analytics: ethical, privacy and security challenges posed to business, industries and society

“…Continued. Big Data Analytics adoption in SCM or the potential of Big Data Analytics with regards to enhancing the innovation and product design capabilities across the supply chain were not touched upon Chelbi et al (2020). and Ben Daya et al (2019) stated several opportunities that will emerge when SCM intersects with Big…”

Empowering Manufacturing Environments with Process Mining-Based Statistical Process Control

“…[46] This paper explores the integration of Industry 4.0 technologies and SPC methodologies in facilities management, highlighting the role of PM in improving operational efficiency. [47] This paper explores the integration of PM techniques and SPC tools in designing control charts and production/maintenance policies for unreliable manufacturing systems, enhancing reliability and quality. [48] This paper proposes a condition-based maintenance optimization method for motorized spindles integrating a proportional hazard model with SPC charts, demonstrating how combining PM techniques with SPC can enhance maintenance scheduling and reliability in industrial settings.…”

Fundamentals of Quality Concept: Literature Review

“…Thus, in the literature, the different models associated with integrated industrial management strategies treated by Bahria et al (2020) can be classified as follows:…”

“…According to Bahria et al (2020), the performance of production systems largely depends on the integration of maintenance, production and quality. The joint consideration of these functions results in insignificant savings in operational costs on the one hand and an improvement in the efficiency of the production system on the other hand.…”