Opportunistic maintenance modeling for series production systems based on bottleneck by considering energy consumption and market demand

IF 4 Q2 ENGINEERING, INDUSTRIAL Journal of Industrial and Production Engineering Pub Date : 2023-07-19 DOI:10.1080/21681015.2023.2234377
A. Salmasnia, Amir Shabani
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Abstract

ABSTRACT Nowadays, series production systems are broadly used in various branches of industry. In these kinds of production systems, any disruption in production flow can significantly increase production cost and time; therefore, a proper maintenance strategy considerably reduces the company’s costs and enhance organizational performance. In this research, a novel bottleneck-centered opportunistic maintenance policy for a series production line is proposed. First of all, the bottleneck is detected by the Lowest Production Rate method. Then, preventive maintenance time interval, reliability threshold, and number of maintenance cycles are determined by the particle swarm optimization algorithm. Finally, a novel opportunistic maintenance strategy is proposed based on analyzing the cost savings of preventive maintenance advancement and postponement. To demonstrate the model’s effectiveness, the proposed bottleneck-based opportunistic maintenance model is compared with two other maintenance models, and the results confirmed that the proposed strategy could efficiently eliminate unnecessary production breaks and achieve cost reduction. Graphical abstract
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考虑能耗和市场需求的基于瓶颈的批量生产系统机会维护模型
如今,系列生产系统被广泛应用于各个工业部门。在这类生产系统中,生产流程中的任何中断都会显著增加生产成本和时间;因此,适当的维护策略可以大大降低公司的成本并提高组织绩效。本文提出了一种以瓶颈为中心的系列生产线机会维护策略。首先,采用最低产量法检测瓶颈。然后利用粒子群优化算法确定预防性维护时间间隔、可靠性阈值和维护周期数;最后,在分析预防性维修提前和延期成本节约的基础上,提出了一种新的机会性维修策略。为了验证该模型的有效性,将基于瓶颈的机会维修模型与其他两种维修模型进行了比较,结果表明该策略能够有效地消除不必要的生产中断,实现成本的降低。图形抽象
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CiteScore
7.50
自引率
6.70%
发文量
21
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