Journal of Korean Society of Industrial and Systems Engineering (산업경영시스템학회지)

Society of Korea Industrial and System Engineering (한국산업경영시스템학회)
권호 표지
DOI QR코드

DOI QR Code

Determination of Resetting Time to the Process Mean Shift with Failure

고장을 고려한 공정평균 이동에 대한 조정시기 결정

  • Lee, Do-Kyung (School of Industrial Engineering, Kumoh National Institute of Technology)
  • Received : 2019.11.13
  • Accepted : 2019.12.11
  • Published : 2019.12.31
Download PDF
⟨ Previous Next ⟩

Abstract

All machines deteriorate in performance over time. The phenomenon that causes such performance degradation is called deterioration. Due to the deterioration, the process mean of the machine shifts, process variance increases due to the expansion of separate interval, and the failure rate of the machine increases. The maintenance model is a matter of determining the timing of preventive maintenance that minimizes the total cost per wear between the relation to the increasing production cost and the decreasing maintenance cost. The essential requirement of this model is that the preventive maintenance cost is less than the failure maintenance cost. In the process mean shift model, determining the resetting timing due to increasing production costs is the same as the maintenance model. In determining the timing of machine adjustments, there are two differences between the models. First, the process mean shift model excludes failure from the model. This model is limited to the period during the operation of the machine. Second, in the maintenance model, the production cost is set as a general function of the operating time. But in the process mean shift model, the production cost is set as a probability functions associated with the product. In the production system, the maintenance cost of the equipment and the production cost due to the non-confirming items and the quality loss cost are always occurring simultaneously. So it is reasonable that the failure and process mean shift should be dealt with at the same time in determining the maintenance time. This study proposes a model that integrates both of them. In order to reflect the actual production system more accurately, this integrated model includes the items of process variance function and the loss function according to wear level.

Keywords

References

  1. Arcelus, F.J., Banerjee, P.K., and Chandra, R., Optimal Production Run for a Normally Distributed Quality Characteristics Exhibiting Non-Negative Shifts in Process Mean and Variance, IIE Transactions, 1982, Vol. 14, No. 2, pp. 90-98. https://doi.org/10.1080/05695558208974587
  2. Barlow, R. and Hunter, L., Optimum Preventive Maintenance Policies, Operations Research, 1960, Vol. 8, No. 1, pp. 90-100. https://doi.org/10.1287/opre.8.1.90
  3. Ben-Daya, M., The economic production lot-sizing problem with imperfect production processes and imperfect maintenance, International Journal of Production Economics, 2002, Vol. 76, No. 3, pp. 257-264. https://doi.org/10.1016/S0925-5273(01)00168-2
  4. Boyles, R.A., The Taguchi Capability Index, Journal of Quality Technology, 1991, Vol. 23, No. 1, pp. 17-26. https://doi.org/10.1080/00224065.1991.11979279
  5. Chen, C.H., Determining the optimum process mean based on Asymmetric Quality Loss Function and Rectifying Inspection Plan, IEEE : Industrial Engineering Management Conference, 2004, pp. 1080-1084.
  6. Gibra, I.N., Optimal Control Processes Subject to Linear Trends, The Journal of Industrial Engineering, 1967, Vol. 18, pp. 35-41.
  7. Hunter W.G. and Kartha, C.D., Determining the Most Profitable Target Value for a Production Process, Journal of Quality Technology, 1977, Vol. 9, No. 4, pp. 176-180. https://doi.org/10.1080/00224065.1977.11980794
  8. Kamat, S.J., A Smoothed Bayes Control of a Variable Quality Characteristic with Linear Shift, Journal of Quality Technology, 1976, Vol. 8, No. 2, pp. 98-104. https://doi.org/10.1080/00224065.1976.11980724
  9. Lee, D.K., Determination of the Resetting Time to the Process Mean Shift based on the Cpm+, Journal of Society of Korea Industrial and Systems Engineering, 2018, Vol. 41, No. 1, pp. 110-117. https://doi.org/10.11627/jkise.2018.41.1.110
  10. Lee, J.H., Park T.H., Kwon H.M., Hong S.H., and Lee, M.K., Optimum target values for manufacturing processes when drifting rate in the process mean is normally distributed, Journal of the Korean Society for Quality Management, 2010, Vol. 38, No. 4, pp. 98-104.
  11. Liao, G.-L., Chen, Y.H., and Sheu, S.-H., Optimal economic production quantity policy for imperfect process with imperfect repair and maintenance, European Journal of Operational Research, 2009, Vol. 195, No. 2, pp. 348-357. https://doi.org/10.1016/j.ejor.2008.01.004
  12. Makis, V., Optimal tool replacement with asymmetric quadratic loss, IIIE Transaction, 1996, Vol. 28, No. 6, pp. 463-466. https://doi.org/10.1080/07408179608966292
  13. Manuele, J., Control Chart for Determining Tool Wear, Industrial Quality Control, 1945, Vol. 1, No. 6, pp. 7-10.
  14. Park, K.S., Optimal Wear-Limit Replacement with Wear Dependent Failures, IEEE Transactions on Reliability, 1988, Vol. 37, No. 3, pp. 293-294. https://doi.org/10.1109/24.3757
  15. Pierskalla. W.P. and Voelker, J.A., A Survey of Maintenance Models : The Control of Surveillance of Deteriorating System, Naval Research Logistics Quarterly, 1976, Vol. 23, No. 3, pp. 353-338. https://doi.org/10.1002/nav.3800230302
  16. Porteus, E.L., Optimal lot sizing, process quality improvement and setup cost reduction, Operations Research, 1986, Vol. 34, No. 1, pp. 137-144. https://doi.org/10.1287/opre.34.1.137
  17. Rahim, M.A. and Tuffaha F., Integrated Model for Determining the Optimal Initial Settings of the Process Mean and the Optimal Production Run Assuming Quadratic Loss Functions, International Journal of Production Research, 2004, Vol. 42, No. 16, pp. 3281-3300. https://doi.org/10.1080/00207540410001666233
  18. Rosenblatt, M.J. and Lee, H.L., Economic production cycles with imperfect production processes, IIE Transactions, 1986, Vol. 18, No. 1, pp. 48-55. https://doi.org/10.1080/07408178608975329
  19. Springer, C.H., A Method for Determining the Most Economic Position of a Process Mean, Industrial Quality Control, 1951, Vol. 8, pp. 36-39.
  20. Sule, D.R. and Harmon, B., Determination of Coordinated Maintenance Scheduling Frequencies for a Group of Machines, AIIE Transactions, 1979, Vol. 11, No. 1, pp. 540-548.
  21. Valdez-Flores, C. and Feldman, R.M., A Survey of Preventive Maintenance Models for Stochastically Deteriorating Single-Unit System, Naval Research Logistics, 1989, Vol. 36, No. 4, pp. 419-446. https://doi.org/10.1002/1520-6750(198908)36:4<419::AID-NAV3220360407>3.0.CO;2-5