model of maintenance planning

with quality control and

production decision for
improving operational
performance
P R AV I N P. TA M B E A N D M A K A R A N D S . K U L K A R N I
(RELIABILITY ENGINEERING AND SYSTEM SAFETY 226 (2022) 108681)

JURNAL REVIEW
 BACKGROUND
1. Tight competition among
producer/manufacturer
2. Critical challenge for manufacturing
industry
3. Deterioration system during processing
4. Not have long enough time to inspect
all components
 FORMULATIONS
1. How to establish integrated model of
maintenance planning with quality
control and production
2. How to improve operational performance
through minimize operational cost
(compare integrated and individual)
3. How to comparison method of GA, SA,
and conventional
 GOALS
1. Establish integrated model of
maintenance planning with quality
control and production
2. Improve operational performance
through minimize operational cost
(compare integrated and individual)
3. Comparison method of GA, SA, and
conventional
 ASUMPTIONS
1. The machine can process one batch at a
time
2. All the batches to be processed are
available at the beginning
3. The batch processing time includes the
sum of the processing times of its
jobs and the setup time
4. Pre-emption of batches is not possible
 ASUMPTIONS (2)
5. The process shift from a good state to
a bad state cannot restore
automatically unless corrective
measures are taken
6. Whenever the process moves to out-of-
control, it produces defective
products
until it resumes to an in-control
RESEARCH METHOD

1. Math model
2. Comparison of genetic
algorithm, simulated
annealing, conventional,
integrated, and individual
 SYSTEM DESC.

1. Multi-component system with continuous

operation
2. Degradation and increasing failure rate
3. After working period, it has break
period to maintain but not long enough
 SYSTEM DESC. (2)
4. Only few components are maintained,
involve repair and replace
5. Each batch also inspected by QC
(sampling-based)
6. Jobs machine processing should be
well-
prepared
OBJECTIVE FUNCTION
Minimize total operational cost
of three aspects :
1. Replacement cost
2. Repairment cost
3. Expected cost of corrective
action
1. Replacement cost
2. Repairment cost
3. Expected cost of corrective action
1. Process cycle length
2. Process quality cost
1. Process cycle length
2. Process quality cost
1. Tardiness penalty cost
2. Penalty cost due to component
failure during batch
processing
1. Tardiness penalty cost
2. Penalty cost due to component
failure during batch processing
CONSTRAINTS
 CONSTRAINTS
1. Each production schedule position
receives one job
2. Each job assign one position in
schedule
3. System availability resulting form
maintenance decision
4. Total available time for completing
maintenance activities
5. Only one maintenance action at a time
 RESULTS

1. Integrated
2. Individual
3. Genetic Algorithm
4. Simulated Annealing
5. Conventional Method
 RESULTS
1. Availability
 RESULTS
2. Quality Process Cost
 RESULTS
3. Schedule Penalty Cost
 RESULTS
4. Total Cost (Comparison Method)
 RESULTS
5. Computational Time (Comparison Method)
 CONCLUSIONS
1. Integrated model already established in
previous slide
2. Integrated system has better
significant saving cost and
availability than individual
3. SA and GA are better than conventional
 SUGGESTIONS
1. Multiple machines and complex
products
2. Other algorithm and other
metaheuristic, ACO, PSO
3. Distributed maintenance
planning and agent-based
scheduling
 THIS RESEARCH
1. Contributions
 Knowledge development of integrated
model
 Design of model integrated calculator

2. Novelty
 Product-sequence on 3 aspects with
integrated model
 Combine methods (PSO, ACO, etc.)
 Multi machines, multi product,
THANK YOU