Skip to main content
SpringerLink
Log in

A novel approach for production scheduling of a high pressure die casting machine subjected to selective maintenance and a sampling procedure for quality control

  • Original Article
  • Published:
International Journal of System Assurance Engineering and Management Aims and scope Submit manuscript

Abstract

Effective maintenance keeps machines in good working condition, improving the machine availability during production. It also minimizes the process failure rate due to component failure, resulting into improved product quality. In this paper the interrelationship between maintenance, production scheduling and quality control is captured using an integrated approach. A mathematical model comprising of total cost of selective maintenance, process quality control using a sampling procedure and production scheduling is developed for a single machine manufacturing system. Simultaneous optimization using the proposed integrated model results into the decision on maintenance actions namely repair, replace and do-nothing for each component, along with the values of parameters for the sampling procedure and the optimal production schedule. A numerical study is presented to demonstrate the applicability of the proposed model. A simulated annealing algorithm is used for obtaining the near optimal solution to the decision parameters. The effectiveness of the proposed approach is compared with the conventional approach of decision making for maintenance, quality control and production scheduling. The results indicate that integrated approach is better as compared to the conventional approach.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6

Similar content being viewed by others

Abbreviations

AReq :

Required system availability

α:

Age reduction factor for component

β:

Weibull shape parameter for component

η:

Weibull scale parameter for component (h)

CC:

Cost of component (Rs.)

Cf :

Failure cost for component (Rs.)

CLP :

Cost of lost production (Rs.)

CLM :

Labour cost of maintenance (Rs./h)

Csp :

Cost of sub-components and consumables (Rs.)

CR :

Replacement cost for component (Rs.)

Cr :

Repair cost for component (Rs.)

CRL:

Cost of loss of residual life (Rs.)

E[Nf]FC2 :

Expected number of failure of the machine during the operating period leading to FC2

E(DT):

Expected downtime (h)

E[TC]M :

Expected total cost of selective maintenance (Rs.)

E[TC]M/Q :

Expected total cost of maintenance with quality control(M/Q) decision (Rs.)

ML:

Mean life (h)

MRL:

Mean residual life (h)

MTTrA:

Mean time to repair for component (h)

MTTRA:

Mean time to replacement for component (h)

MTTCA:

Mean time to corrective action for component (h)

PR:

Production rate (units/h)

ℜ i :

Index of i-th component undergoing replacement work

ri :

Index of i-th component undergoing repair work

Ri :

Reliability of i-th component

Ri(t/T):

Conditional reliability of i-th component having survived upto time T

RF:

Restoration factor for component

TPMS :

Time between the current maintenance and next expected opportunity (h)

TAvl :

Time available to carry out maintenance work (h)

TLM :

Time elapsed between the last maintenance and opportunity (h)

TCf :

Total cost of random failures (Rs.)

TCR :

Total cost of replacement (Rs.)

TCr :

Total cost of repair (Rs.)

vi :

Effective age of i-th component at the end of any period (h)

(vi)o :

Effective age of i-th component at the opportunity (h)

(v’i)o :

Effective age of i-th component after maintenance at the opportunity (h)

αs :

Type 1 error of sampling procedure

βs :

Type 2 error of sampling procedure

τ:

Expected time of occurrence of assignable cause (h)

ARLIn :

Average run length in in-control state

ARLOut :

Average run length in out-of-control state

ATS:

Average time to signal

C s :

Acceptance number

Cins :

Cost of inspection (Rs.)

Cac :

Cost of investigating the assignable cause (Rs./h)

CF :

Cost of investigating the false alarm (Rs./h)

CRej :

Cost of rejection per piece (Rs.)

CRes :

Cost of repairing/restoring the process (Rs.)

CRew :

Cost of rework (Rs. per unit)

E[Csampling]:

Expected total cost of sampling per cycle (Rs.)

E[CFalse Alarm]:

Expected total cost of false alarms per cycle (Rs.)

E[CRejections]:

Expected total cost of rejections (Rs.)

E[CACD]:

Expected total cost of assignable cause detection (Rs.)

E[CRestore]:

Expected total cost to restore the process (Rs.)

E[CPQC]cycle :

Expected cost of process quality control per cycle (Rs.)

E[CRework]:

Expected total cost of rework. (Rs.)

E[N]cycles :

Expected number of cycles

E[T]cycle :

Expected cycle length of process quality control

E[T]false :

Expected total time for investigation of false alarm (h)

E[TC]PQC :

Expected total cost of process quality control (Rs.)

Hs :

Time between samples (h)

Ns :

Sample Size

P1 :

Average proportion of defectives during in-control

P2 :

Average proportion of defectives during out-of-control

Sin :

Expected number of samples in in-control state

TF :

Time required to investigate false alarm (h)

TS :

Time required for sampling (h)

T1:

Expected time to search the assignable cause (h)

T2:

Expected time to restore the process (h)

λ:

Overall process failure rate

λE :

Process failure rate due to external causes

λM :

Process failure rate due to machine component failure

bk :

k-th batch in production schedule

Ch:

Inventory holding cost per item per unit time (Rs./item/h)

CT:

Completion time of a batch (h)

DD:

Due date for a batch (h)

E[TC]PS :

Expected total schedule penalty cost (Rs.)

E[TC]Integrated :

Expected total cost of integrated model (Rs.)

F(bk)i :

Probability of failure of i-th component during k-th batch processing

IHC:

Inventory holding cost (Rs.)

LT:

Lateness of a batch (h)

LTF :

Lateness of a batch due to component failure (h)

P:

Processing time of a batch (h)

ST:

Start time of the batch

Tk :

Tardiness penalty of k-th batch

Td :

Delay time due to component failure (h)

W:

Penalty cost for the batch (Rs./h)

References

  • Batun S, Azizoglu M (2009) Single machine scheduling with preventive maintenances. Int J Prod Res 47(7):1753–1771

    Article  MATH  Google Scholar 

  • Ben-Daya M (1999) Integrated production maintenance and quality model for imperfect processes. IIE Trans 31:491–501

    Google Scholar 

  • Ben-Daya M, Duffuaa SO (1995) Maintenance and quality: the missing link. J Qual Maint Eng 1(1):1355–2511

    Article  Google Scholar 

  • Ben-Daya M, Duffuaa SO (2003) Integration of Taguchi’s loss function approach in the economic design of \( \bar{x} \)-chart. Int J Qual Reliab Manage 20 (5): 607–619

  • Ben-Daya M, Rahim MA (2000) Effect of maintenance on the economic design of \( \bar{x} \)-control chart. Eur J Oper Res 120 (1): 131–143

    Google Scholar 

  • Cassady CR, Kutanoglu E (2003) Minimizing job tardiness using integrated preventive maintenance planning and production scheduling. IIE Trans 35:503–513

    Article  Google Scholar 

  • Cassady CR, Kutanoglu E (2005) Integrating preventive maintenance planning and production scheduling for a single machine. IEEE Trans Reliab 54(2):304–309

    Article  Google Scholar 

  • Cassady CR, Bowden RO, Liew L, Pohl EA (2000) Combining preventive maintenance and statistical process control: a preliminary investigation. IIE Trans 32(6):471–478

    Article  Google Scholar 

  • Chen W, Yu F, Guh R, Lin Y (2011) Economic design of \( \bar{x} \)-control charts under preventive maintenance and Taguchi loss functions. J Appl Oper Res 3 (2): 103–109

  • Chiu HN, Huang BS (1996) The economic design of \( \bar{x} \)-control chart under preventive maintenance policy. J Qual Maint Eng 13 (1): 61–71

  • Ebeling CE (2010) An introduction to reliability and maintainability engineering. Tata McGraw-Hill Education Private Limited, New Delhi

    Google Scholar 

  • Gao X, Barabady J, Markeset T (2010) Criticality analysis of a production facility using cost importance measures. Int J Syst Assur Eng Manage 1:17–23

    Google Scholar 

  • Gustafson A, Schunnesson H, Galar D, Kumar U (2013) Production and maintenance performance analysis: manual versus semi-automatic LHDs. J Qual Maint Eng 19(1):74–88

    Article  Google Scholar 

  • Hadidi LA, Al-Turki UM, Rahim A (2012) Integrated models in production planning and scheduling, maintenance and quality: a review. Int J Ind Sys Eng 10(1):21–50

    Google Scholar 

  • Hamadani AZ, Khorshidi HA (2013) System reliability optimization using time value of money. Int J Adv Manuf Technol 66:97–106

    Article  Google Scholar 

  • Ho LL, Quinino RC (2012) Integrating on-line process control and imperfect corrective maintenance: an economical design. Eur J Oper Res 222:253–262

    Article  MATH  MathSciNet  Google Scholar 

  • Hoseinie SH, Khalokakaie R, Ataei M, Kumar U (2011) Reliability-based maintenance scheduling of haulage system of drum shearer. Int J Min Miner Eng 3(1):26–37

    Google Scholar 

  • Ji M, He Y, Cheng T (2007) Single-machine scheduling with periodic maintenance to minimize makespan. Comput Oper Res 34(6):1764–1770

    Article  MATH  MathSciNet  Google Scholar 

  • Kacem I, Chu C, Souissi A (2008) Single-machine scheduling with an availability constraint to minimize the weighted sum of the completion times. Comput Oper Res 35:827–844

    Article  MATH  MathSciNet  Google Scholar 

  • Kijima M, Morimura H, Suzuki Y (1988) Periodical replacement problem without assuming minimal repair. Eur J Oper Res 37:183–186

    Article  MathSciNet  Google Scholar 

  • Kirkpatrick S, Gelatt CD Jr, Vecchi MP (1983) Optimization by simulated annealing. Science 220(4598):671–680

    Article  MATH  MathSciNet  Google Scholar 

  • Lee CY, Liman SD (1992) Single machine flow-time scheduling with scheduled maintenance. Acta Inform 29:375–382

    Article  MATH  MathSciNet  Google Scholar 

  • Lee BH, Rahim MA (2001) An integrated economic design model for quality control, replacement and maintenance. Qual Eng 13(4):581–593

    Article  Google Scholar 

  • Lee CY, Yu G (2007) Single machine scheduling under potential disruption. Oper Res Lett 35(4):541–548

    Article  MATH  MathSciNet  Google Scholar 

  • Linderman K, McKone-Sweet KE, Anderson JC (2005) An integrated systems approach to process control and maintenance. Eur J Oper Res 164:324–340

    Article  MATH  Google Scholar 

  • Lorenzen TJ, Vance LC (1986) The economic design of control charts: a unified approach. Technometrics 28(1):3–10

    Article  MATH  MathSciNet  Google Scholar 

  • Low C, Ji M, Hsu CJ, Su CT (2010) Minimizing the makespan in a single machine scheduling problems with flexible and periodic maintenance. App Math Model 34:334–342

    Article  MATH  MathSciNet  Google Scholar 

  • Marais KB, Saleh JH (2009) Beyond its cost, the value of maintenance: an analytical framework for capturing its net present value. Eng Syst Saf 94:644–657

    Article  Google Scholar 

  • Mehrafrooz Z, Noorossana R (2011) An integrated model based on statistical process control and maintenance. Comput Ind Eng 61:1245–1255

    Article  Google Scholar 

  • Montgomery DC (2002) Introduction to statistical quality control, 4th edn. Wiley, New Delhi

    Google Scholar 

  • Mosheiov G, Sarig A (2009) Scheduling a maintenance activity to minimize total weighted completion-time. Comput Math Appl 57:619–623

    Article  MATH  MathSciNet  Google Scholar 

  • Ollila A, Malmipuro M (1999) Maintenance has a role in quality. TQM Mag 11(1):17–21

    Article  Google Scholar 

  • Pan E, Liao W, Xi L (2010) Single-machine-based production scheduling model integrated preventive maintenance planning. Int J Adv Manuf Technol 50:365–375

    Article  Google Scholar 

  • Panagiotidou S, Nenes G (2009) An economically designed, integrated quality and maintenance model using an adaptive Shewhart chart. Reliab Eng Syst Saf 94:732–741

    Article  Google Scholar 

  • Panagiotidou S, Tagaras G (2010) Statistical process control and condition-based maintenance: a meaningful relationship through data sharing. Prod Oper Manage 19(2):156–171

    Article  Google Scholar 

  • Panagiotidou S, Tagaras G (2012) Optimal integrated process control and maintenance under general deterioration. Reliab Eng Syst Saf 104:58–70

    Article  Google Scholar 

  • Pandey D, Kulkarni MS, Vrat P (2010) Joint consideration of production scheduling, maintenance and quality policies: a review and conceptual framework. Int J Adv Oper Manage 2(1/2):1–24

    Google Scholar 

  • Pandey D, Kulkarni MS, Vrat P (2011) A methodology for joint optimization for maintenance planning, process quality and production scheduling. Comput Ind Eng 61(4):1098–1106

    Article  Google Scholar 

  • Pandey D, Kulkarni MS, Vrat P (2012) A methodology for simultaneous optimization of design parameters for the preventive maintenance and quality policy incorporating Taguchi loss function. Int J Prod Res 50(7):2030–2045

    Article  Google Scholar 

  • Qi X, Chen T, Tu F (1999) Scheduling the maintenance on a single machine. J Oper Res Soc 50:1071–1078

    Article  MATH  Google Scholar 

  • Rahim MA, Banerjee PK (1993) A generalized model for the economic design of \( \bar{x} \)-control charts for production systems with increasing failure rate and early replacement. Nav Res Logist 40 (6): 789–809

    Google Scholar 

  • Sanlaville E, Schmidt G (1998) Machine scheduling with availability constraints. Acta Inform 35(9):795–811

    Article  MATH  MathSciNet  Google Scholar 

  • Sortrakul N, Cassady CR (2007) Genetic algorithms for total weighted expected tardiness integrated preventive maintenance planning and production scheduling for a single machine. J Qual Maint Eng 13(1):49–61

    Article  Google Scholar 

  • Sule DR (2007) Production planning and industrial scheduling, 2nd edn. CRC Press, Boca Raton

    Google Scholar 

  • Tagaras G (1988) An integrated cost model for the joint optimization of the process control and maintenance. J Oper Res Soc 39(8):757–766

    Article  MATH  Google Scholar 

  • Tam ASB, Chan WM, Price JWH (2007) Maintenance scheduling to support the operation of manufacturing and production assets. Int J Adv Manuf Technol 34:399–405

    Article  Google Scholar 

  • Verma AK, Srividya A, Ramesh PG (2010) A systems approach to integrated E-maintenance of large engineering plants. Int J Syst Assur Eng Manage 1(3):239–245

    Google Scholar 

  • Wang S, Liu M (2013) A branch and bound algorithm for single-machine production scheduling integrated with preventive maintenance planning. Int J Prod Res 51(3):847–868

    Article  Google Scholar 

  • Wang G, Sun H, Chu C (2005) Preemptive scheduling with availability constraints to minimize total weighted completion times. Ann Oper Res 133:183–192

    Article  MATH  MathSciNet  Google Scholar 

  • Wong CS, Chan FTS, Chung SH (2013) A joint production scheduling approach considering multiple resources and preventive maintenance tasks. Int J Prod Res 51(3):883–896

    Article  Google Scholar 

  • Yanez M, Joglar F, Modarres M (2002) Generalized renewal process for analysis of repairable systems with limited failure experience. Reliab Eng Syst Saf 77:167–180

    Article  Google Scholar 

  • Yulan J, Zuhua J, Wenrui H (2008) Multi-objective integrated optimization research on preventive maintenance planning and production scheduling for a single machine. Int J Adv Manuf Technol 39(9–10):954–964

    Article  Google Scholar 

  • Zhang T, Nakamura M (2005) Reliability-based optimal maintenance scheduling by considering maintenance effect to reduce cost. Qual Reliab Eng Int 21:203–220

    Article  Google Scholar 

  • Zhou W, Zhu G (2008) Economic design of integrated model of control chart and maintenance management. Math Comput Model 47:1389–1395

    Article  MATH  MathSciNet  Google Scholar 

  • Zhou X, Lu Z, Xi L (2012) Preventive maintenance optimization for a multi-component system under changing job shop schedule. Reliab Eng Syst Saf 101:14–20

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology Delhi, Hauz Khas, New Delhi, 110016, India

    Pravin P. Tambe & Makarand S. Kulkarni

Authors
  1. Pravin P. Tambe
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Makarand S. Kulkarni
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Pravin P. Tambe.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Tambe, P.P., Kulkarni, M.S. A novel approach for production scheduling of a high pressure die casting machine subjected to selective maintenance and a sampling procedure for quality control. Int J Syst Assur Eng Manag 5, 407–426 (2014). https://doi.org/10.1007/s13198-013-0183-4

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s13198-013-0183-4

Keywords

Search

Navigation