Maintenance scheduling and production control of multiple-machine manufacturing systems

This paper deals with the production and preventive maintenance control problem for a multiple-machine manufacturing system. The objective of such a problem is to find the production and preventive maintenance rates for the machines so as to minimize the total cost of inventory/backlog, repair and preventive maintenance. A two-level hierarchical control model is presented, and the structure of the control policy for both identical and non-identical manufacturing systems is described using parameters, referred to here as input factors. By combining analytical formalism with simulation-based statistical tools such as experimental design and response surface methodology, an approximation of the optimal control policies and values of input factors are determined. The results obtained extend those available in existing literature to cover non-identical machine manufacturing systems. A numerical example and a sensitivity analysis are presented in order to illustrate the robustness of the proposed approach. The extension of the proposed production and preventive maintenance policies to cover large systems (multiple machines, multiple products) is discussed.     

Maintenance costs and makespan minimization for assembly permutation flow shop scheduling by considering preventive and corrective maintenance

The joint optimization of production scheduling and maintenance planning has a significant influence on production continuity and machine reliability. However, limited research considers preventive maintenance (PM) and corrective maintenance (CM) in assembly permutation flow shop scheduling. This paper addresses the bi-objective joint optimization of both PM and CM costs in assembly permutation flow shop scheduling. We also propose a new mixed integer linear programming model for the minimization of the makespan and maintenance costs. Two lemmas are inferred to relax the expected number of failures and CM cost to make the model linear. A restarted iterated Pareto greedy (RIPG) algorithm is applied to solve the problem by including a new evaluation of the solutions, based on a PM strategy. The RIPG algorithm makes use of novel bi-objective-oriented greedy and referenced local search phases to find non-dominated solutions. Three types of experiments are conducted to evaluate the proposed MILP model and the performance of the RIPG algorithm. In the first experiment, the MILP model is solved with an epsilon-constraint method, showing the effectiveness of the MILP model in small-scale instances. In the remaining two experiments, the RIPG algorithm shows its superiority for all the instances with respect to four well-known multi-objective metaheuristics.     

Availability optimisation of repairable system with preventive maintenance policy

This article investigates optimal steady availability of a repairable system with six states. Both preventive maintenance and corrective maintenance are considered in this article. By probability argument, the system is described as an abstract Cauchy problem. Using the method of strong continuous semi-group theory, we derive the steady availability of the system. Finally, the optimal time to carry out preventive maintenance is analysed theoretically and numerical examples are presented.     

An optimal production and inspection strategy with preventive maintenance error and rework

This study considers the integrated problem of production, preventive maintenance (PM), inspection, and inventory for an imperfect production process where rework and PM error exist. PM is performed when the process is in a controlled state. The correct implementation of PM results in a lower system failure rate, whereas a PM error results in the system shifting to the out-of-control state with a certain probability. The age of the system after PM is correlated with the level of PM performed. When the process in an out-of-control state produces a certain percentage of non-conforming items, we assume that a certain proportion of the non-conforming items can be reworked into conforming items. In a deteriorating production system, we determine the optimal inspection interval, inspection frequency, and production quantity that will yield the maximal unit expected profit. Numerical analyses are used to investigate the effectiveness of imperfect PM and to explore the effect of rework and PM error on profit.     

The optimal process mean problem: Integrating predictability and profitability into an experimental factor space

For complex manufacturing systems, process or product optimization can be instrumental in achieving a significant economic advantage. To reduce costs associated with product non-conformance or excessive waste, engineers often identify the most critical quality characteristics and then use methods to obtain their ideal parameter settings. The optimal process mean problem is one such statistical method; it begins with the assumption of the characteristic parameters, whereby the ideal settings are determined based upon the tradeoff among various processing costs. Unfortunately, however, the ideal parameter settings for a characteristic mean can be unpredictable, as it is directly influenced by changes in the process variability, tolerance, and cost structure. In this paper, a method is proposed that relates the optimal process mean to the ideal settings through experimental design. With the method, one may gain greater predictability of the new optimal process mean when the process conditions are altered. The methodology is illustrated for a process with multiple mixed quality characteristics; such an optimal process mean problem is seldom treated in the literature.     

An optimal control approach to the optical flow problem

The optical flow problem is reduced to an optimal control problem governed by a linear parabolic equation having the unknown velocity field (the optical flow) as drift term. This model is derived from a new assumption, that is, the brightness intensity is conserved on a moving pattern driven by a Gaussian stochastic process. The optimality conditions are deduced by a passage to the limit technique in an approximating optimal control problem introduced for a regularization purpose. Finally, the controller uniqueness is addressed.     

Joint production,inspection and maintenance control policies for deteriorating system under quality constraint

This paper studies the integration of production, sampling inspection and age-based maintenance planning for an unreliable production system subject to gradual deterioration. The deterioration process of the production unit has a twofold effect on its reliability and product quality. To mitigate the effects of such deterioration, an age-based major maintenance can be conducted, which denotes a perfect repair that restores the production unit to initial conditions. The quality control is performed through a sampling plan that inspects a fraction of the parts produced. The problem further considers that the optimal decision must be determined under a constraint on the outgoing quality required by the final customer. In this domain, standard sampling procedures are applicable only to production process that are statistically stable and under control. Nevertheless, such sampling plans disregard the interaction with production management and maintenance issues and they do not consider the effects of deterioration. In this paper a new joint control policy considering the interactions between production-quality and maintenance is proposed. A stochastic mathematical model is developed through specialized optimization techniques to solve such quality constrained problem. Numerical examples are provided to illustrate the usefulness of the proposed approach and to study the interactions between production-quality and maintenance strategies. An extensive sensitivity analysis and a comparative study are conducted to illustrate the effectiveness of the obtained joint control policy.     

A simulation optimization approach in production planning of failure prone manufacturing systems

In this paper, the implementation of a new method to control the production rate of manufacturing systems, based on the combination of stochastic optimal control theory, discrete event simulation, experimental design and response surface methodology is outlined. The system under study consists of several parallel machines, multiple-product manufacturing system. Machines are subject to failures and repairs and their capacity process is assumed to be a finite state Markov chain throughout the analytical control model. The problem is to choose the production rates so as to minimize the expected discounted cost of inventory/backlog over an infinite horizon. We first show that, for constant demand rates and exponential failure and repair times distributions of the machines, the hedging point policy is optimal. The structure of the hedging point policy is then parameterized by factors representing the thresholds of involved products. With such a policy, simulation experiments are combined to experimental design and response surface methodology to estimate the optimal control policy. We obtain that the hedging point policy is also applicable to a wide variety of complex problems including non-exponential failure and repair times distributions and random demand rates. Analytical solutions may not be easily obtained for such complex situations.     

Application of agent based modelling to aircraft maintenance manning and sortie generation

This research develops an agent based simulation model for application to the sortie generation process, focusing on a single fighter aircraft unit. The simulation includes representations of each individual maintainer within the unit, along with supervisory agents that provide direction in the form of dynamic task prioritization and resource assignment. Using a high-fidelity depiction of each entity, an exploration of the effects of different mixes of skill levels and United States Air Force Specialty Codes (AFSCs) on sortie production is performed. Analysis is conducted using an experimental design with results presented demonstrating the effects of maintenance manning decisions on the Combat Mission Readiness (CMR) of a fighter unit.     

Maximum principle for the stochastic optimal control problem with delay and application

In this paper, we consider an optimal control problem for the stochastic system described by stochastic differential equations with delay. We obtain the maximum principle for the optimal control of this problem by virtue of the duality method and the anticipated backward stochastic differential equations. Our results can be applied to a production and consumption choice problem. The explicit optimal consumption rate is obtained.     

Multivariable norm optimal iterative learning control with auxiliary optimisation

The paper describes a substantial extension of norm optimal iterative learning control (NOILC) that permits tracking of a class of finite dimensional reference signals whilst simultaneously converging to the solution of a constrained quadratic optimisation problem. The theory is presented in a general functional analytical framework using operators between chosen real Hilbert spaces. This is applied to solve problems in continuous time where tracking is only required at selected intermediate points of the time interval but, simultaneously, the solution is required to minimise a specified quadratic objective function of the input signals and chosen auxiliary (state) variables. Applications to the discrete time case, including the case of multi-rate sampling, are also summarised. The algorithms are motivated by practical need and provide a methodology for reducing undesirable effects such as payload spillage, vibration tendencies and actuator wear whilst maintaining the desired tracking accuracy necessary for task completion. Solutions in terms of NOILC methodologies involving both feedforward and feedback components offer the possibilities of greater robustness than purely feedforward actions. Results describing the inherent robustness of the feedforward implementation are presented and the work is illustrated by experimental results from a robotic manipulator.     

Optimization process for configuration of flexible joined-wing

An optimized configuration design utilizing both structural and aerodynamic analyses of a flexible joined-wing configuration is presented in this paper. The joined-wing aircraft concept fulfills a proposed long-endurance surveillance mission and incorporates a load-bearing antenna structure embedded in the wing skin. Aerodynamic, structural, and optimization analyses are completed a number of times. A range of joined-wing configurations were trimmed for critical flight conditions and then structurally optimized for trimmed flight and gust loads to achieve a minimum weight for each configuration. A response surface statistical analysis was then applied to determine optimal joined-wing aircraft configurations. The response surface showed trends in the design of lightweight joined-wing aircraft. The revised version of this paper was presented at the 10th MAO Multidisciplinary Analysis and Optimization Conference, August 30–September 1, 2004.     

A genetic algorithm based approach to optimal fixture configuration

In this paper the application of genetic algorithms (GAs) to the fixture configuration optimisation problem is presented. A general purpose fixturing verification system has been developed to check the validity of individual fixture configurations by analysing various contact types in the workpiece-fixture system. Based on the information provided by the verification system, a genetic algorithm based approach carries out the evaluation process to determine the most statically stable fixture configuration among a large number of candidates. The preliminary implementation is introduced to demonstrate the ability of GAs and two different coding schemes are tested to explain their influence on the performance of GAs.     

On the worst-case disturbance of minimax optimal control

We consider a minimax optimal control problem for uncertain stochastic systems. The uncertainty in the underlying stochastic system is formulated in terms of probability measure perturbations satisfying a relative entropy constraint. By characterizing the worst-case measure for a related stochastic minimax game, it is shown that the worst-case uncertain system can be represented in the form of a parametric perturbation of the nominal system. A numerical example is presented to illustrate theoretical results developed in this paper.     

Stochastic optimal control of networked control systems with control packet dropouts

This paper considers the stochastic optimal control problem for networked control systems(NCSs)with control packet dropouts.The proportional plus up to the third-order derivative(PD3)compensation strategy is adopted to compensate for control packet dropouts at the actuator by using the past control packets stored in the buffer.Based on the strategy,a new NCS structure model with packet dropouts is provided,where the packet dropout is assumed to obey the Bernoulli random binary distribution.In terms of the given model,the stochastic optimal control law is proposed. Numerical examples illustrate the effectiveness of the results.     

A multipoint version of space mapping optimization applied to vehicle crashworthiness design

In this paper, space mapping (SM) technique is combined with response surface methodology (RSM). SM is an optimization method well suited for very costly problems to find an improved design with fulfilled constraints. The SM technique use less costly models, which complements the correct models. The theory is established and compared to the corrected RSM. A multipoint version of SM is presented, where a separate evaluation is done in each iteration to improve the mapping function. Using this additional evaluation to update the mapping function, generally, the number of iterations to find the optimum solution can be reduced. Thus, the elapsed time to solve the optimization problem can be reduced if a parallel computer is utilized. Finally, one engineering optimization problem is solved to illustrate the application of SM in vehicle crashworthiness structural optimization.     

An optimal production lot-sizing problem for an imperfect process with imperfect maintenance and inspection time length

This article develops an integrated model in considering the situations of an imperfect process with imperfect maintenance and inspection time for the joint determination of both economic production quantity (EPQ) and preventive maintenance (PM). This imperfect process has a general deterioration distribution with increasing hazard rate. Even with periodic PM, such a production system cannot be recovered as good as new. This means that the system condition depends on how long it runs. Also, the PM level can be distinct due to the maintenance cost. For convenience, it is assumed the age of system is reduced in proportional to the PM level. Further, during a production cycle, we need an inspection to see if the process is in control. This inspection might demand a considerable amount of time. In this article, we take PM level and inspection time into consideration to optimise EPQ with two types of out-of-control states. To see how the method works, we use a Weibull shock model to show the optimal solutions for the least costs.     

离散事件系统仿真中的优化算法

计算机仿真是研究离散事件系统的一类重要方法。在仿真环境下对离散事件系统的参数进行优化是设计高性能系统的必要保证。本文给出了随机型优化问题的分类，并综述了离散 参数和连续参数随机型优化问题中典型的求解算法。