Estimation of active maintenance opportunity windows in Bernoulli production lines

Abstract Effective and timely maintenance actions can sustain and improve both system availability and product quality in automated manufacturing systems. However, arbitrarily stopping machines for maintenance will occupy their production time and may introduce system-level production losses. There may exist hidden opportunities during production, such that specific machines can be actively shut down for preventive maintenance without penalizing the system throughput. In this paper, the time intervals for such opportunities are defined as active maintenance opportunity windows (AMOWs). A Bernoulli model is developed to analytically estimate AMOWs in two-machine-one-buffer production lines. A recursive algorithm based on an aggregation method is used to estimate AMOWs in long lines. For balanced production lines, a heuristic algorithm is proposed to estimate AMOWs in real time. The effectiveness of the methods has been validated through numerical studies.

[1]  Jionghua Jin,et al.  Algebraic expression of system configurations and performance metrics for mixed-model assembly systems , 2014 .

[2]  Semyon M. Meerkov,et al.  Transient behavior of serial production lines with Bernoulli machines , 2008 .

[3]  Jingshan Li,et al.  Throughput analysis of production systems: recent advances and future topics , 2009 .

[4]  Mandyam M. Srinivasan,et al.  Production-Inventory Systems with Preventive Maintenance , 1996 .

[5]  Jun Ni,et al.  Decision support systems for effective maintenance operations , 2012 .

[6]  Sheldon M. Ross,et al.  Stochastic Processes , 2018, Gauge Integral Structures for Stochastic Calculus and Quantum Electrodynamics.

[7]  Ki Ling Cheung,et al.  Joint determination of preventive maintenance and safety stocks in an unreliable production environment , 1997 .

[8]  Xiaojun Zhou,et al.  Dynamic maintenance decision-making for series-parallel manufacturing system based on MAM-MTW methodology , 2012, Eur. J. Oper. Res..

[9]  Hans Wortmann,et al.  Condition based maintenance in the context of opportunistic maintenance , 2012 .

[10]  S. Jack Hu,et al.  Allocation of maintenance resources in mixed model assembly systems , 2013 .

[11]  Lirong Cui,et al.  Opportunistic Maintenance for Multi-component Shock Models , 2006, Math. Methods Oper. Res..

[12]  Sofiene Dellagi,et al.  Joint integrated production-maintenance policy with production plan smoothing through production rate control , 2017 .

[13]  Stephan Biller,et al.  Transient analysis of Bernoulli serial lines: performance evaluation and system-theoretic properties , 2013 .

[14]  Dirk Cattrysse,et al.  Joint maintenance and inventory optimization systems: A review , 2013 .

[15]  Benoît Iung,et al.  Opportunistic maintenance based on multi-dependent components of manufacturing system , 2016 .

[16]  Stanley B. Gershwin,et al.  Manufacturing Systems Engineering , 1993 .

[17]  Rommert Dekker,et al.  Optimal maintenance of multi-component systems: a review , 2008 .

[18]  Stephan Biller,et al.  Maintenance opportunity planning system , 2007 .

[19]  Anis Chelbi,et al.  Analysis of a production/inventory system with randomly failing production unit submitted to regular preventive maintenance , 2004, Eur. J. Oper. Res..

[20]  John A. Buzacott,et al.  Stochastic models of manufacturing systems , 1993 .

[21]  Donghua Zhou,et al.  Joint optimization of preventive maintenance and inventory policies for multi-unit systems subject to deteriorating spare part inventory , 2015 .

[22]  Jun Ni,et al.  Preventive maintenance opportunities for large production systems , 2015 .

[23]  Xi Gu.  The impact of maintainability on the manufacturing system architecture , 2017 .

[24]  Jun Ni,et al.  Prediction of Passive Maintenance Opportunity Windows on Bottleneck Machines in Complex Manufacturing Systems , 2015 .

[25]  E. G. Kyriakidis,et al.  Optimal preventive maintenance of a production system with an intermediate buffer , 2006, Eur. J. Oper. Res..

[26]  Tangbin Xia,et al.  Production-driven opportunistic maintenance for batch production based on MAM-APB scheduling , 2015, Eur. J. Oper. Res..

[27]  Jay Lee,et al.  Maintenance priority assignment utilizing on-line production information , 2007 .

[28]  Yoram Koren,et al.  The Global Manufacturing Revolution: Product-Process-Business Integration and Reconfigurable Systems , 2010 .