Extended economic production quantity models with preventive maintenance

Document Type : Article

Authors

1 Department of Industrial Engineering, Faculty of Engineering, University of Kashan, Kashan, P.O. Box 8731753153, Iran

2 Department of Management and Entrepreneurship, Faculty of Humanities, University of Kashan, Kashan, P.O. Box 1471835191, Iran

Abstract

This paper generalizes the standard economic production quantity (EPQ) model in process manufacturing industry by incorporating regular preventive maintenance (PM) activities into classic EPQ model. The PM program improves the condition of the production to an acceptable level, and avoids potential stoppages and disruptions, hence, it is a vital task in every production process. However, the standard EPQ model does not consider PM activities and then is not applicable to real-world situations. We consider manufacturer which produces a product under EPQ setting with a defective production process, in which every production cycle involves a number of sub-production cycles. Two models are proposed, based on the disposal time of defective items, to determine optimal number of sub-production cycles. In model I, the disposal of defective items is performed once per cycle at the end of each production cycle, while in model II, the disposal of defective items is performed multiple times per cycle, at the end of each sub-production cycle. The total cost functions are derived for each model separately, and then simple solution algorithms are designed. A numerical example is presented and discussed to evaluate proposed models. The results illustrate that model II is more cost effective than model I.

Keywords

Main Subjects


References
1. Jain, M. and Rathore, S. Economic production quantity
models with Shortage, price and stock-dependent
Demand for deteriorating items", IJE Transactions,
20(2), pp. 159{166 (2007).
2. Pan, E., Jin, Y., Wang, S., and Cang, T. An
integrated EPQ model based on a control chart for an
imperfect production process", International Journal
of Production Research, 50(23), pp. 6999{7011 (2012).
3. Khedlekar, U.K. A disruption production model with
exponential demand", International Journal of Industrial
Engineering Computations, 3(4), pp. 607{616
(2012).
4. Wee, H.M., Wang, W.T., and Yang, P.C. A production
quantity model for imperfect quality items
with shortage and screening constraint", International
Journal of Production Research, 51(6), pp. 1869{1884
(2013).
5. Dash, B., Pattnaik, M., and Pattnaik, H. Deteriorated
Economic Production Quantity (EPQ) model for
declined quadratic demand with time value of money
and shortages", Applied Mathematical Sciences, 8(73),
pp. 3607{3618 (2014).
6. Karimi-Nasab, M. and Sabri-Laghaie, K. Developing
approximate algorithms for EPQ problem with
process compressibility and random error in producH.
Mokhtari and J. Asadkhani/Scientia Iranica, Transactions E: Industrial Engineering 27 (2020) 3253{3264 3263
tion/inspection", International Journal of Production
Research, 52(8), pp. 2388{2421 (2014).
7. Nasr, W.W., Salameh, M.K., and Moussawi-Haidar, L.
Integrating the economic production model with deteriorating
raw material over multi-production cycles",
International Journal of Production Research, 52(8),
pp. 2477{2489 (2014).
8. Pacheco-Velazquez, E.A. and Cardenas-Barron, L.E.
An economic production quantity inventory model
with backorders considering the raw material costs",
Scientia Iranica, 23(2), pp. 736{746 (2016).
9. Jawad, H., Jaber, M.Y., Bonney, M., and Rosen, M.A.
Deriving an exergetic economic production quantity
model for better sustainability", Applied Mathematical
Modelling, 40(11{12), pp. 6026{6039 (2016).
10. Sadeghi, J., Akhavan Niaki, S.T., Malekian, M.R.,
and Sadeghi, S. Optimizing multi-item economic
production quantity model with trapezoidal fuzzy demand
and backordering: two tuned meta-heuristics",
European Journal of Industrial Engineering, 10(2), pp.
170{195 (2016).
11. Al-Salamah, M. Economic production quantity in
batch manufacturing with imperfect quality, imperfect
inspection, and destructive and non-destructive acceptance
sampling in a two-tier market", Computers &
Industrial Engineering, 93, pp. 275{285 (2016).
12. Mokhtari, H., Naimi-Sadigh, A., and Salmasnia, A. A
computational approach to economic production quantity
model for perishable products with backordering
shortage and stock-dependent demand", Scientia Iranica,
24(4), pp. 2138{2151 (2017).
13. Mokhtari, H. and Rezvan, M.T. A single-supplier,
multi-buyer, multi-product VMI production-inventory
system under partial backordering", Operational Research,
20(1), pp. 1{21 (2020). DOI: 10.1007/s12351-
017-0311-z
14. Nasr, W.W., Salameh, M., and Moussawi-Haidar,
L. Economic production quantity with maintenance
interruptions under random and correlated yields",
International Journal of Production Research, 55(16),
pp. 4544{4556 (2017).
15. Karmakar, S., Kumar De, S., and Goswami, A. A
pollution sensitive dense fuzzy economic production
quantity model with cycle time dependent production
rate", Journal of Cleaner Production, 154, pp. 139{
150 (2017).
16. Nobil, A.H., Sedigh, A.H.A., and Cardenas-Barron,
L.E. Multi-machine economic production quantity for
items with scrapped and rework with shortages and
allocation decisions", Scientia Iranica, Transaction E,
Industrial Engineering, 25(4), pp. 2331{2346 (2018).
17. Wee, H.M., Fu, K., Chen, Z., and Zhang, Y. Optimal
production inventory decision with learning and
fatigue behavioral e ect in labor intensive manufacturing",
Scientia Iranica, 27(2), pp. 1{42 (2020). DOI:
10.24200/SCI.2018.50614.1788
18. Rezg, N., Dellagi, S., and Chelbi, A. Joint optimal
inventory control and preventive maintenance policy",
International Journal of Production Research, 46(19),
pp. 5349{5365 (2008).
19. Radhoui, M., Rezg, N., and Chelbi, A. Integrated
model of preventive maintenance, quality control and
bu er sizing for unreliable and imperfect production
systems", International Journal of Production Research,
47(2), pp. 389{402 (2009).
20. Liao, G.L. and Sheu, S.H. Economic production
quantity model for randomly failing production process
with minimal repair and imperfect maintenance", International
Journal of Production Economics, 130(1),
pp. 118{124 (2011).
21. Sana, S.S. Preventive maintenance and optimal bu er
inventory for products sold with warranty in an imperfect
production system", International Journal of
Production Research, 50(23), pp. 6763{6774 (2012).
22. Wee, H.M. and Widyadana, G.A. Economic production
quantity models for deteriorating items with
rework and stochastic preventive maintenance time",
International Journal of Production Research, 50(11),
pp. 2940{2952 (2012).
23. Pal, B., Sana, S.S., and Chaudhuri, K. A mathematical
model on EPQ for stochastic demand in an imperfect
production system", Journal of Manufacturing
Systems, 32(1), pp. 260{270 (2013).
24. Chen, Y.C. An optimal production and inspection
strategy with preventive maintenance error and rework",
Journal of Manufacturing Systems, 32(1), pp.
99{106 (2013).
25. Jafari, L. and Makis, V. Optimal lot-sizing and maintenance
policy for a partially observable production
system", Computers & Industrial Engineering, 93, pp.
88{98 (2016).
26. Sett, B.K., Sarkar, S., and Sarkar, B. Optimal
bu er inventory and inspection errors in an imperfect
production system with preventive maintenance",
The International Journal of Advanced Manufacturing
Technology, 90(1{4), pp. 545{560 (2017).
27. La Fata, C.M. and Passannanti, G. A simulated
annealing-based approach for the joint optimization
of production/inventory and preventive maintenance
policies", The International Journal of Advanced
Manufacturing Technology, 91(9{12), pp. 3899{3909
(2017).
28. Lai, X., Chen, Z., and Bidanda, B. Optimal decision
of an economic production quantity model for imperfect
manufacturing under hybrid maintenance policy
with shortages and partial backlogging", International
Journal of Production Research, 57(19), pp. 1{25
(2019). DOI: 10.1080/00207543.2018.1562249