Selective maintenance optimization under schedule and quality constraints

Abstract

Purpose – The traditional practice for maintenance, quality control and production scheduling is to plan independently irrespective of an interrelationship exist between them. The purpose of this paper is to develop an approach for integrating maintenance, quality control and production scheduling. The objective is to investigate the benefits of the integrated effect in terms of the expected total cost of system operation of the three functions. Design/methodology/approach – The proposed approach is based on the conditional reliability of the components. Cost model for integrating selective maintenance, quality control using sampling-based procedure and production scheduling is developed using the conditional reliability. An integrated approach is such that, first an optimal schedule for the batches to be processed is obtained independently while the maintenance and quality control decisions are optimized considering the optimal schedule on the machine. The expected total cost of conventional approach, i.e. “No integration” is calculated to compare the effectiveness of integrated approach. Findings – The integrated approach have shown a higher cost saving as compared to the independent planning approach. The approach is practical to implement as the results are obtained in a reasonable computational time. Practical implications – The approach presented in this paper is generic and can be applied at planned as well as unplanned opportunities. The proposed integrated approach is dynamic in nature, as during maintenance opportunities, it is possible to optimize the decision on maintenance, quality control and production scheduling considering the current age of components and production requirement. Originality/value – The originality of the paper is in the approach for integration of the three elements of shop floor operations that are usually treated separately and rarely touched upon by researchers in the literature.

Ranking maintenance strategies for sustainable maintenance plan in manufacturing systems using fuzzy axiomatic design principle and fuzzy-TOPSIS

“…Given the well-developed literature streams on maintenance from one perspective, and quality from the other perspective, scholars attempt to match specific parameters of one area to the other, mainly in the context of manufacturing systems. Tambe and Kulkarni (2016) built up a template to merge maintenance, scheduling of production activities and quality control to decide on the advantages of the merged effects. The method was tuned towards the conditional reliability of associated units.…”

Machine criticality based maintenance prioritization

“…Maintenance optimization can be done on a single machine. An integrated approach for maintenance selection, quality control, and production scheduling is presented in Tambe and Kulkarni (2016). However, optimization of multiple machines in a system is also needed.…”

Selective Maintenance Policy for a Series-Parallel System Considering Maintenance Priority of Components

“…These breaks between successive missions provide an opportunity to perform maintenance on the component of the system. However, restricted to the limited maintenance resources, such as budget, time, and manpower, etc., it may not be possible to perform all desirable maintenance activities for the component in the system [1]- [4]. In such circumstance, only an optimal subset of maintenance actions among all the options is chosen to ensure that the subsequent mission is successfully completed.…”