Industrial Engineering and Management Systems

Korean Institute of Industrial Engineers (대한산업공학회)
권호 표지

Integrating Machine Reliability and Preventive Maintenance Planning in Manufacturing Cell Design

  • Das, Kanchan (East Carolina University) ;
  • Lashkari, R.S. (University of Windsor) ;
  • Sengupta, S. (Oakland University)
  • Published : 2008.09.30
Download PDF
⟨ Previous Next ⟩

Abstract

This paper presents a model for designing cellular manufacturing systems (CMS) by integrating system cost, machine reliability, and preventive maintenance (PM) planning. In a CMS, a part is processed using alternative process routes, each consisting of a sequence of visits to machines. Thus, a level of 'system reliability' is associated with the machines along the process route assigned to a part type. Assuming machine reliabilities to follow the Weibull distribution, the model assigns the machines to cells, and selects, for each part type, a process route which maximizes the overall system reliability and minimizes the total costs of manufacturing operations, machine underutilization, and inter-cell material handling. The model also incorporates a reliability based PM plan and an algorithm to implement the plan. The algorithm determines effective PM intervals for the CMS machines based on a group maintenance policy and thus minimizes the maintenance costs subject to acceptable machine reliability thresholds. The model is a large mixed integer linear program, and is solved using LINGO. The results point out that integrating PM in the CMS design improves the overall system reliability markedly, and reduces the total costs significantly.

Keywords

References

  1. Askin, R. G. and Estrada, S. (1999), Investigation of cellular manufacturing practices. In S. A. Irani (ed), Handbook of Cellular Manufacturing Systems, Wiley, New York, Chapter 1, 25-34.
  2. Cho, I. D., and Parlar, M. (1991), A survey of maintenance models for multi-unit systems. European Journal of Operational Research, 51, 1-23. https://doi.org/10.1016/0377-2217(91)90141-H
  3. Das, K., Lashkari, R.S., Sengupta, S. (2006), Integration of machine reliability and preventive maintenance planning in the design of cellular manufacturing systems, Proceedings of 7th Asia Pacific Industrial Engineering Management Systems Conference, Bangkok, Thailand, 1103 -1113.
  4. Das, K., Lashkari, R. S., Sengupta, S. (2005), A study of preventive maintenance planning for CMS. Proceedings of the 1st International Conference on Operations and Supply Chain Management, Bali, Indonesia, 21-28.
  5. Diallo, M., Perreval, H., and Quillot, A. (2001), Manufacturing cell design with flexible routing capability in presence of unreliable machines. International Journal of Production Economics, 74, 175-182. https://doi.org/10.1016/S0925-5273(01)00124-4
  6. Dekker, R., Van Der Schouten, F., and Wilderman, R. (1997), A review of multi-component maintenance models with economic dependence, Mathematical Methods of Operational Research, 45, 411-435. https://doi.org/10.1007/BF01194788
  7. Ebeling, C. E. (1997), An Introduction to Reliability and Maintainability Engineering, McGraw-Hill, New York.
  8. Jardine, A. K. S. and Tsang, A. H. C (2006), Maintenance, Replacement and Reliability, CRC Press, Boca Raton, FL.
  9. Jeon, G., Broering, M., Leep, H. R., Parsaei, H. R., and Wong, J. P. (1998), Part family formation based on alternative routes during machine failure. Computers and Industrial Engineering, 35, 73-76. https://doi.org/10.1016/S0360-8352(98)00023-0
  10. Johnson, L. G. (1959), The statistical treatment of fatigue experiments, Research Laboratories, General Motors Corporation, IVA, 105.
  11. Joines, J. A., King, R. E., and Culbreth, C. T. (1996), A comprehensive review of production-oriented manufacturing cell formation techniques. International Journal of Flexible Automation and Intelligent Manufacturing, 3, 161-120.
  12. Kardon, B., and Fredendall, L. D. (2002), Incorporating overall probability of system failure into a preventive maintenance model for a serial system. Journal of Quality in Maintenance Engineering, 8, 331-345. https://doi.org/10.1108/13552510210448531
  13. Logendran, R., and Talkington, D. (1997), Analysis of cellular and functional manufacturing system in the presence of machine breakdown. International Journal of Production Economics, 53, 239-256. https://doi.org/10.1016/S0925-5273(97)00100-X
  14. Mansouri, S. A., Husseini, S. M. M., and Newman, S. T. (2000), A review of modern approaches to multicriteria cell design. International Journal of Production Research, 38, 1201-1218. https://doi.org/10.1080/002075400189095
  15. Seifoddini, S., and Djassemi, M. (2001), The effect of reliability consideration on the application of quality index. Computers and Industrial Engineering, 40, 65-77. https://doi.org/10.1016/S0360-8352(00)00072-3
  16. Selim, H. M, Askin, R. G., and Vakharia, A. (1998), Cell formation in group technology: review, evaluation and directions for future research. Computers and Industrial Engineering, 34, 3-20. https://doi.org/10.1016/S0360-8352(97)00147-2
  17. Talukder, M. S., and Knapp, G. M. (2002), Equipment assignment to multiple overhaul blocks in series system, Journal of Quality in Maintenance Engineering, 8, 319-330. https://doi.org/10.1108/13552510210448522
  18. Valdez-Flores, C., and Feldman, R. M. (1989), A survey of preventive maintenance models for stochastically deteriorating single unit systems. Naval Research Logistics, 36, 419-446. https://doi.org/10.1002/1520-6750(198908)36:4<419::AID-NAV3220360407>3.0.CO;2-5
  19. Wang, H. (2002), A survey of maintenance policies of deteriorating systems: invited review, European Journal of Operational Research, 139, 469-489. https://doi.org/10.1016/S0377-2217(01)00197-7
  20. Wilderman, R. E., Dekker, R., and Smit, A. C. J. M. (1997), A dynamic policy for grouping maintenance activities, European Journal of Operational Research, 99, 530-551. https://doi.org/10.1016/S0377-2217(97)00319-6
  21. Wemmerlov, U., and Hyer, N. L. (1986), Procedures for the part family machine group identification problem in cellular manufacturing, Journal of Operations Management, 6, 12-147.