Integrated Preventive Maintenance Scheduling Model with Redundancy for Cutting Tools on a Single Machine

  • L. S. Tavassoli Department of Industrial Manufacturing and Systems Engineering, University of Texas at Arlington, USA
  • N. Sakhavand Department of Industrial Manufacturing and Systems Engineering, University of Texas at Arlington, USA
  • S. S. Fazeli Department of Industrial and System Engineering, Wayne State University, USA
Volume: 10 | Issue: 6 | Pages: 6542-6548 | December 2020 | https://doi.org/10.48084/etasr.3903

Abstract

In this paper, we present an integrated multi-objective framework of a single machine for a single cutting tool problem. Our maintenance policy is based on performing minimal repairs in case of a minor failure and Preventive Maintenance (PM) to avoid a major failure that results in the replacement of the tool. This framework allows simultaneous optimization of the two conflicting time and cost objectives. A redundant system is proposed as a part of the model to assist the production line under a major failure. In addition, the tool’s preventive maintenance time is synchronized with the completion of the machine tool’s work cycle to reduce the machine’s set-up time. The model was optimized using a customized Non-dominated Sorting Genetic Algorithm (NSGA-II). An experimental study based on real-market data was conducted and the results were compared with the ones obtained from classical methods.

Keywords: preventive maintenance, redundancy, non-dominated sorting genetic algorithm, time and cost trade-off, maintenance scheduling, multi-objective optimization

Downloads

Download data is not yet available.

References

S. P. Canto, "Application of Benders' decomposition to power plant preventive maintenance scheduling," European Journal of Operational Research, vol. 184, no. 2, pp. 759-777, Jan. 2008. DOI: https://doi.org/10.1016/j.ejor.2006.11.018

J. A. C. Duarte, J. C. T. A. Craveiro, and T. P. Trigo, "Optimization of the preventive maintenance plan of a series components system," International Journal of Pressure Vessels and Piping, vol. 83, no. 4, pp. 244-248, Apr. 2006. DOI: https://doi.org/10.1016/j.ijpvp.2006.02.016

G. Budai, R. Dekker, and R. P. Nicolai, "Maintenance and Production: A Review of Planning Models," Econometric Institute Research Papers, EI 2006-44, 2006.

T. Sooktip, N. Wattanapongsakorn, and D. W. Coit, "System reliability optimization with k-out-of-n subsystems and changing k," in The Proceedings of 2011 9th International Conference on Reliability, Maintainability and Safety, Guiyang, China, Jun. 2011, pp. 1382-1387. DOI: https://doi.org/10.1109/ICRMS.2011.5979487

Y. Liu, H. Huang, Z. Wang, Y. Li, and Y. Yang, "A Joint Redundancy and Imperfect Maintenance Strategy Optimization for Multi-State Systems," IEEE Transactions on Reliability, vol. 62, no. 2, pp. 368-378, Jun. 2013. DOI: https://doi.org/10.1109/TR.2013.2259193

D. R. Fulkerson, "A Network Flow Computation for Project Cost Curves," Management Science, vol. 7, no. 2, pp. 167-178, 1961. DOI: https://doi.org/10.1287/mnsc.7.2.167

J. E. Kelley, "Critical-Path Planning and Scheduling: Mathematical Basis," Operations Research, vol. 9, no. 3, pp. 296-320, 1961. DOI: https://doi.org/10.1287/opre.9.3.296

Xiaodong Yao, M. Fu, S. I. Marcus, and E. Fernandez-Gaucherand, "Optimization of preventive maintenance scheduling for semiconductor manufacturing systems: models and implementation," in Proceedings of the 2001 IEEE International Conference on Control Applications (CCA'01) (Cat. No.01CH37204), Sep. 2001, pp. 407-411.

X. Yao, E. Fernandez-Gaucherand, M. C. Fu, and S. I. Marcus, "Optimal preventive maintenance scheduling in semiconductor manufacturing," IEEE Transactions on Semiconductor Manufacturing, vol. 17, no. 3, pp. 345-356, Aug. 2004. DOI: https://doi.org/10.1109/TSM.2004.831948

H. Shirmohammadi, Z. G. Zhang, and E. Love, "A Computational Model for Determining the Optimal Preventive Maintenance Policy With Random Breakdowns and Imperfect Repairs," IEEE Transactions on Reliability, vol. 56, no. 2, pp. 332-339, Jun. 2007. DOI: https://doi.org/10.1109/TR.2007.896747

R. V. Canfield, "Cost Optimization of Periodic Preventive Maintenance," IEEE Transactions on Reliability, vol. 35, no. 1, pp. 78-81, Apr. 1986. DOI: https://doi.org/10.1109/TR.1986.4335355

C. R. Cassady and E. Kutanoglu, "Integrating preventive maintenance planning and production scheduling for a single machine," IEEE Transactions on Reliability, vol. 54, no. 2, pp. 304-309, Jun. 2005. DOI: https://doi.org/10.1109/TR.2005.845967

M. Vanhoucke and D. Debels, "The discrete time/cost trade-off problem: extensions and heuristic procedures," Journal of Scheduling, vol. 10, no. 4, pp. 311-326, Oct. 2007. DOI: https://doi.org/10.1007/s10951-007-0031-y

C. Su and Y. Liu, "Multi-objective imperfect preventive maintenance optimisation with NSGA-II," International Journal of Production Research, vol. 58, no. 13, pp. 4033-4049, Jul. 2020. DOI: https://doi.org/10.1080/00207543.2019.1641237

J. T. Saraiva, M. L. Pereira, V. T. Mendes, and J. C. Sousa, "A Simulated Annealing based approach to solve the generator maintenance scheduling problem," Electric Power Systems Research, vol. 81, no. 7, pp. 1283-1291, Jul. 2011. DOI: https://doi.org/10.1016/j.epsr.2011.01.013

M. Samrout, F. Yalaoui, E. Châtelet, and N. Chebbo, "New methods to minimize the preventive maintenance cost of series-parallel systems using ant colony optimization," Reliability Engineering & System Safety, vol. 89, no. 3, pp. 346-354, Sep. 2005. DOI: https://doi.org/10.1016/j.ress.2004.09.005

S. Rajendran, A. Ansaripour, M. K. Srinivasan, and M. J. Chandra, "Stochastic goal programming approach to determine the side effects to be labeled on pharmaceutical drugs," IISE Transactions on Healthcare Systems Engineering, vol. 9, no. 1, pp. 83-94, Jan. 2019. DOI: https://doi.org/10.1080/24725579.2018.1488157

E. Taghizadeh, M. Abedzadeh, and M. Setak, "A Multi Objective Reliable Location-Inventory Capacitated Disruption Facility Problem with Penalty Cost Solve with Efficient Meta Historic Algorithms," arXiv:1711.09400 [cs, stat], Nov. 2017, Accessed: Dec. 04, 2020. [Online]. Available: http://arxiv.org/abs/1711.09400.

A. Ansaripour, A. Mata, S. Nourazari, and H. Kumin, "Some Explicit Results for the Distribution Problem of Stochastic Linear Programming," Open Journal of Optimization, vol. 5, no. 4, pp. 140-162, Dec. 2016. DOI: https://doi.org/10.4236/ojop.2016.54014

P. Abbasian, N. Mahdavi-Amiri, and H. Fazlollahtabar, "Multiple utility constrained multi-objective programs using Bayesian theory," Journal of Industrial Engineering International, vol. 14, no. 1, pp. 111-118, Mar. 2018. DOI: https://doi.org/10.1007/s40092-017-0211-0

H. Fazlollahtabar, P. Abbasian, and N. Mahdavi-Amiri, "Modelling and Optimization of a Non-Constrained Multi-objective Problem having Multiple Utility Functions using Bayesian Theory," Journal of Information Sciences and Computing Technologies, vol. 4, no. 3, pp. 332-342, Oct. 2015.

P. Ghoddousi, E. Eshtehardian, S. Jooybanpour, and A. Javanmardi, "Multi-mode resource-constrained discrete time-cost-resource optimization in project scheduling using non-dominated sorting genetic algorithm," Automation in Construction, vol. 30, pp. 216-227, Mar. 2013. DOI: https://doi.org/10.1016/j.autcon.2012.11.014

H. Jafarzadeh, N. Moradinasab, and M. Elyasi, "An Enhanced Genetic Algorithm for the Generalized Traveling Salesman Problem," Engineering, Technology & Applied Science Research, vol. 7, no. 6, pp. 2260-2265, Dec. 2017. DOI: https://doi.org/10.48084/etasr.1570

K. Soleimani and J. Mazloum, "Designing a GA-Based Robust Controller For Load Frequency Control (LFC)," Engineering, Technology & Applied Science Research, vol. 8, no. 2, pp. 2633-2639, Apr. 2018. DOI: https://doi.org/10.48084/etasr.1592

M. Tavana, K. Khalili-Damghani, D. Di Caprio, and Z. Oveisi, "An evolutionary computation approach to solving repairable multi-state multi-objective redundancy allocation problems," Neural Computing and Applications, vol. 30, no. 1, pp. 127-139, Jul. 2018. DOI: https://doi.org/10.1007/s00521-016-2676-y

A. Afshar, A. K. Ziaraty, A. Kaveh, and F. Sharifi, "Nondominated Archiving Multicolony Ant Algorithm in Time-Cost Trade-Off Optimization," Journal of Construction Engineering and Management, vol. 135, no. 7, pp. 668-674, Jul. 2009. DOI: https://doi.org/10.1061/(ASCE)0733-9364(2009)135:7(668)

M. Rahimi and H. Iranmanesh, "Multi Objective Particle Swarm Optimization for a Discrete Time, Cost and Quality Trade-off Problem," World Applied Sciences Journal, vol. 4, no. 2, pp. 270-276, 2008.

H. Zhang and H. Li, "Multi‐objective particle swarm optimization for construction time‐cost tradeoff problems," Construction Management and Economics, vol. 28, no. 1, pp. 75-88, Jan. 2010. DOI: https://doi.org/10.1080/01446190903406170

K. S. Moghaddam, "Multi-objective preventive maintenance and replacement scheduling in a manufacturing system using goal programming," International Journal of Production Economics, vol. 146, no. 2, pp. 704-716, Dec. 2013. DOI: https://doi.org/10.1016/j.ijpe.2013.08.027

M.-C. Fitouhi and M. Nourelfath, "Integrating noncyclical preventive maintenance scheduling and production planning for a single machine," International Journal of Production Economics, vol. 136, no. 2, pp. 344-351, Apr. 2012. DOI: https://doi.org/10.1016/j.ijpe.2011.12.021

"Products," Sumitomo Electric Hardmetal. https://www.sumitool.com/en/products/ (accessed Dec. 04, 2020).

Metrics

Abstract Views: 84
PDF Downloads: 60

Metrics Information
Bookmark and Share