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Mustapha Nourelfath - One of the best experts on this subject based on the ideXlab platform.
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Integrated Preventive Maintenance and production decisions for imperfect processes
Reliability Engineering and System Safety, 2016Co-Authors: Mustapha Nourelfath, Nabil Nahas, Mohamed Ben-dayaAbstract:This paper integrates production, Maintenance, and quality for an imperfect process in a multi-period multi-product capacitated lot-sizing context. The production system is modeled as an imperfect machine, whose the status is considered to be either in-control or out-of-control. When the machine is out of control, it produces a fraction of nonconforming items. During each period, this machine is inspected and imperfect Preventive Maintenance activities are simultaneously performed to reduce its age, proportional to the Preventive Maintenance level. The objective is to minimize the total cost, while satisfying the demand for all products. Our optimization model allows for a joint selection of the optimal values of production plan, and the Maintenance policy, while taking into account quality related costs. A solution algorithm is developed and illustrative numerical examples are presented. It is found that the increase in PM level leads to reductions in quality control costs. Furthermore, if the cost of performing PM is high to the point where it is not compensated for by reductions in the quality related costs, then performing PM is not justifiable. Finally, using non-periodic Preventive Maintenance with the possibility of different Preventive Maintenance levels may result in an improvement of the total cost.
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integrating noncyclical Preventive Maintenance scheduling and production planning for multi state systems
Reliability Engineering & System Safety, 2014Co-Authors: Mohamed Chahir Fitouhi, Mustapha NourelfathAbstract:This paper integrates noncyclical Preventive Maintenance with tactical production planning in multi-state systems. The Maintenance policy suggests noncyclical Preventive replacements of components, and minimal repair on failed components. The model gives simultaneously the appropriate instants for Preventive Maintenance, and production planning decisions. It determines an integrated lot-sizing and Preventive Maintenance strategy of the system that will minimize the sum of Preventive and corrective Maintenance costs, setup costs, holding costs, backorder costs, and production costs, while satisfying the demand for all products over the entire horizon. The model is first solved by comparing the results of several multi-products capacitated lot-sizing problems. Then, for large-size problems, a simulated annealing algorithm is developed and illustrated through numerical experiments.
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integrating noncyclical Preventive Maintenance scheduling and production planning for a single machine
International Journal of Production Economics, 2012Co-Authors: Mohamed Chahir Fitouhi, Mustapha NourelfathAbstract:This paper deals with the problem of integrating noncyclical Preventive Maintenance and tactical production planning for a single machine. We are given a set of products that must be produced in lots during a specified finite planning horizon. The Maintenance policy suggests possible Preventive replacements at the beginning of each production planning period, and minimal repair at machine failure. The proposed model determines simultaneously the optimal production plan and the instants of Preventive Maintenance actions. The objective is to minimize the sum of Preventive and corrective Maintenance costs, setup costs, holding costs, backorder costs and production costs, while satisfying the demand for all products over the entire horizon. The problem is solved by comparing the results of several multi-product capacitated lot-sizing problems. The value of the integration and that of using noncyclical Preventive Maintenance when the demand varies from one period to another are illustrated through a numerical example and validated by a design of experiment. The later has shown that the integration of Maintenance and production planning can reduce the total Maintenance and production cost and the removal of periodicity constraint is directly affected by the demand fluctuation and can also reduce the total Maintenance and production cost.
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An integrated model for production and Preventive Maintenance planning in multi-state systems
IEEE Transactions on Reliability, 2010Co-Authors: Mustapha Nourelfath, Mohamed Chahir Fitouhi, Mahdi MachaniAbstract:This paper integrates Preventive Maintenance with tactical production planning in multi-state systems. The proposed model coordinates the production with the Maintenance decisions, so that the total expected cost is minimized. We are given a set of products that must be produced in lots on a multi-state production system during a specified finite planning horizon. Planned Preventive Maintenance, and unplanned corrective Maintenance can be performed on each component of the multi-state system. The Maintenance policy suggests cyclical Preventive replacements of components, and a minimal repair on failed components. The objective is to determine an integrated lot-sizing and Preventive Maintenance strategy of the system that will minimize the sum of Preventive and corrective Maintenance costs, setup costs, holding costs, backorder costs, and production costs, while satisfying the demand for all products over the entire horizon. We model the production system as a multi-state system with binary-states, and s-independent components. A method is proposed to evaluate the times and the costs of Preventive Maintenance and minimal repair, and the average production system capacity in each period. We show how the formulated problem can be solved by comparing the results of several multi-product capacitated lot-sizing problems. For large-size problems, a genetic algorithm is developed to deal with the Preventive Maintenance selection task in the integrated planning model.
Mohamed Chahir Fitouhi - One of the best experts on this subject based on the ideXlab platform.
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integrating noncyclical Preventive Maintenance scheduling and production planning for multi state systems
Reliability Engineering & System Safety, 2014Co-Authors: Mohamed Chahir Fitouhi, Mustapha NourelfathAbstract:This paper integrates noncyclical Preventive Maintenance with tactical production planning in multi-state systems. The Maintenance policy suggests noncyclical Preventive replacements of components, and minimal repair on failed components. The model gives simultaneously the appropriate instants for Preventive Maintenance, and production planning decisions. It determines an integrated lot-sizing and Preventive Maintenance strategy of the system that will minimize the sum of Preventive and corrective Maintenance costs, setup costs, holding costs, backorder costs, and production costs, while satisfying the demand for all products over the entire horizon. The model is first solved by comparing the results of several multi-products capacitated lot-sizing problems. Then, for large-size problems, a simulated annealing algorithm is developed and illustrated through numerical experiments.
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integrating noncyclical Preventive Maintenance scheduling and production planning for a single machine
International Journal of Production Economics, 2012Co-Authors: Mohamed Chahir Fitouhi, Mustapha NourelfathAbstract:This paper deals with the problem of integrating noncyclical Preventive Maintenance and tactical production planning for a single machine. We are given a set of products that must be produced in lots during a specified finite planning horizon. The Maintenance policy suggests possible Preventive replacements at the beginning of each production planning period, and minimal repair at machine failure. The proposed model determines simultaneously the optimal production plan and the instants of Preventive Maintenance actions. The objective is to minimize the sum of Preventive and corrective Maintenance costs, setup costs, holding costs, backorder costs and production costs, while satisfying the demand for all products over the entire horizon. The problem is solved by comparing the results of several multi-product capacitated lot-sizing problems. The value of the integration and that of using noncyclical Preventive Maintenance when the demand varies from one period to another are illustrated through a numerical example and validated by a design of experiment. The later has shown that the integration of Maintenance and production planning can reduce the total Maintenance and production cost and the removal of periodicity constraint is directly affected by the demand fluctuation and can also reduce the total Maintenance and production cost.
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An integrated model for production and Preventive Maintenance planning in multi-state systems
IEEE Transactions on Reliability, 2010Co-Authors: Mustapha Nourelfath, Mohamed Chahir Fitouhi, Mahdi MachaniAbstract:This paper integrates Preventive Maintenance with tactical production planning in multi-state systems. The proposed model coordinates the production with the Maintenance decisions, so that the total expected cost is minimized. We are given a set of products that must be produced in lots on a multi-state production system during a specified finite planning horizon. Planned Preventive Maintenance, and unplanned corrective Maintenance can be performed on each component of the multi-state system. The Maintenance policy suggests cyclical Preventive replacements of components, and a minimal repair on failed components. The objective is to determine an integrated lot-sizing and Preventive Maintenance strategy of the system that will minimize the sum of Preventive and corrective Maintenance costs, setup costs, holding costs, backorder costs, and production costs, while satisfying the demand for all products over the entire horizon. We model the production system as a multi-state system with binary-states, and s-independent components. A method is proposed to evaluate the times and the costs of Preventive Maintenance and minimal repair, and the average production system capacity in each period. We show how the formulated problem can be solved by comparing the results of several multi-product capacitated lot-sizing problems. For large-size problems, a genetic algorithm is developed to deal with the Preventive Maintenance selection task in the integrated planning model.
D N P Murthy - One of the best experts on this subject based on the ideXlab platform.
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optimal Preventive Maintenance of leased equipment with corrective minimal repairs
European Journal of Operational Research, 2006Co-Authors: J Jaturonnatee, D N P Murthy, Rein BoondiskulchokAbstract:For leased equipment, the lessor carries out the Maintenance of the equipment. Usually, the contract of lease specifies the penalty for equipment failures and for repairs not being carried out within specified time limits. This implies that optimal Preventive Maintenance policies must take these penalty costs into account and properly traded against the cost of Preventive Maintenance actions. The costs associated with failures are high as unplanned corrective Maintenance actions are costly and the resulting penalties due to lease contract terms being violated. The paper develops a model to determine the optimal parameters of a Preventive Maintenance policy that takes into account all these costs to minimize the total expected cost to the lessor for new item lease. The parameters of the policy are (i) the number of Preventive Maintenance actions to be carried out over the lease period, (ii) the time instants for such actions, and (iii) the level of action.
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optimal periodic Preventive Maintenance policy for leased equipment
Reliability Engineering & System Safety, 2006Co-Authors: J Pongpech, D N P MurthyAbstract:For leased equipment the lessor incurs penalty costs for failures occurring over the lease period and for not rectifying such failures within a specified time limit. Through Preventive Maintenance actions the penalty costs can be reduced but this is achieved at the expense of increased Maintenance costs. The paper looks at a periodic Preventive Maintenance policy which achieves a tradeoff between the penalty and Maintenance costs.
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Warranty and discrete Preventive Maintenance
Reliability Engineering and System Safety, 2004Co-Authors: C. S. Kim, I Djamaludin, D N P MurthyAbstract:Preventive Maintenance actions over the warranty period have an impact on the warranty servicing cost to the manufacturer and the cost to the buyer of fixing failures over the life of the product after the warranty expires. However, Preventive Maintenance costs money and is worthwhile only when these costs exceed the reduction in other costs. The paper deals with a model to determine when Preventive Maintenance actions (which rejuvenate the unit) carried out at discrete time instants over the warranty period are worthwhile. The cost of Preventive Maintenance is borne by the buyer. © 2003 Elsevier Ltd. All rights reserved.
Ali Gharbi - One of the best experts on this subject based on the ideXlab platform.
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improved Preventive Maintenance in the framework of forecasting problem under subcontractor constraint
International Journal of Production Research, 2017Co-Authors: Zied Hajej, Nidhal Rezg, Ali GharbiAbstract:The paper presents a new improved Preventive Maintenance strategy for a forecasting problem of production and Maintenance optimisation under subcontractor constraint. In order to satisfy the customer, the manufacturing system consists of a principal machine M1 and called upon subcontractor machine Ms. Knowing that both machines are subjected to random failures, failure rate of main machine increases with time and according to production rates. An improved Preventive Maintenance strategy is used for control of the machine M1, whereas subcontractor machine Ms is uncontrollable from Preventive Maintenance point of view. An analytic formulation of problem has been proposed in order to determine the economical production plans for M1 and Ms. An improved Maintenance strategy (IMS) is developed in order to minimise the total production loss, when the subcontractor machine is unavailable. It consists of determining the best time to perform Preventive Maintenance actions taking into account production rates, histo...
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joint optimal production control Preventive Maintenance policy for imperfect process manufacturing cell
International Journal of Production Economics, 2012Co-Authors: K Dhouib, Ali Gharbi, M Ben N AzizaAbstract:Abstract Production, Maintenance, and quality are often modeled as separate problems, despite the strong link that exists between these primary components of any manufacturing system. This paper deals with an integrated approach for the joint optimization of production-inventory control and Preventive Maintenance policy for a manufacturing cell comprising an imperfect process where the ‘in-control’ period has a general deterioration distribution. The production-inventory control policy based on the hedging point policy consists of building and maintaining a security stock of finished products in order to respond to demand and to avoid shortages during restoration actions. Restoration actions are planned when the system switches to the ‘out-of-control’ state and starts producing non-conforming items. The manufacturing cell is also subject to an age-based Preventive Maintenance policy in order to reduce the shift rate to the ‘out-of-control’ state. The main objective of this paper is to determine the joint optimal policy that minimizes the overall cost, which is comprised of setup, Maintenance, inventory holding, and shortage costs, as well as the cost incurred by producing non-conforming items. A mathematical model is proposed, and the expression of the overall incurred cost is derived and used as a basis for the optimal determination of the joint production-inventory control and Preventive Maintenance policy. These issues are illustrated using numerical examples. It is found that performing Preventive Maintenance will yield reductions in the overall incurred cost. Sensitivity analyses are also carried out in order to illustrate the robustness of the proposed methodology.
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simultaneous control of production repair replacement and Preventive Maintenance of deteriorating manufacturing systems
International Journal of Production Economics, 2011Co-Authors: F Dehayem I Nodem, Jeanpierre Kenne, Ali GharbiAbstract:This paper presents a method to find the optimal production, repair/replacement and Preventive Maintenance policies for a degraded manufacturing system. The system is subject to random machine failures and repairs. The status of the system is deemed to degrade with repair activities. When a failure occurs, the machine is either repaired or replaced, and a replacement action renews the machine, while a repair action brings it to a degraded operational state, with the next repair time increasing as the number of repairs increases as well. A Preventive Maintenance action is considered in order to improve the reliability of the machine, thereby reducing the amount of disruptions caused by machine failures. The decision variables are the production rate, the Preventive Maintenance rate and the repair/replacement switching policy upon machine failure. The objective of the study is to find the decision variables that minimize the overall cost, including repair, replacement, Preventive Maintenance, inventory holding and backlog costs over an infinite planning horizon. The proposed model is based on a semi-Markov decision process, and the stochastic dynamic programming method is used to obtain the optimality conditions. A numerical example is given to illustrate the proposed model, and a sensitivity analysis is considered in order to confirm the structure of the control policy and to illustrate the usefulness of the proposed approach.
Mahdi Machani - One of the best experts on this subject based on the ideXlab platform.
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An integrated model for production and Preventive Maintenance planning in multi-state systems
IEEE Transactions on Reliability, 2010Co-Authors: Mustapha Nourelfath, Mohamed Chahir Fitouhi, Mahdi MachaniAbstract:This paper integrates Preventive Maintenance with tactical production planning in multi-state systems. The proposed model coordinates the production with the Maintenance decisions, so that the total expected cost is minimized. We are given a set of products that must be produced in lots on a multi-state production system during a specified finite planning horizon. Planned Preventive Maintenance, and unplanned corrective Maintenance can be performed on each component of the multi-state system. The Maintenance policy suggests cyclical Preventive replacements of components, and a minimal repair on failed components. The objective is to determine an integrated lot-sizing and Preventive Maintenance strategy of the system that will minimize the sum of Preventive and corrective Maintenance costs, setup costs, holding costs, backorder costs, and production costs, while satisfying the demand for all products over the entire horizon. We model the production system as a multi-state system with binary-states, and s-independent components. A method is proposed to evaluate the times and the costs of Preventive Maintenance and minimal repair, and the average production system capacity in each period. We show how the formulated problem can be solved by comparing the results of several multi-product capacitated lot-sizing problems. For large-size problems, a genetic algorithm is developed to deal with the Preventive Maintenance selection task in the integrated planning model.
