Joint production preventive maintenance and dynamic inspection for a degrading manufacturing system

In this paper, an integrated production, maintenance, and quality control strategy for a degradation production system is presented. Production system is impacted by production rates and subject to random failure as well as quality deterioration. The production system under the forecasting problem is composed of a degrading machine producing one type of product to satisfy the random demand with a given service level. During a finite horizon, the production variation from period to other influences the machine degradation as well as the failure rate that consequently impacts the product quality. In order to decrease the defective rate, increase the system availability, and satisfy the random demand under service level, a novel policy of production, maintenance, and quality control is proposed. Face to quality deterioration, and differently to traditional sampling inspections standards (such as ISO 2859,..) which is only based on quality requirements, this study proposes a new quality control based on interactions with production and maintenance strategies under degradation constraint. Thus, the proposed dynamic sampling strategy takes into account the failure rate impacted by the variation of production rate. In order to minimize the total cost and satisfy the random demand under service level and quality constraints, the present study aims to establish an economical production policy as well as a maintenance strategy and a quality control policy taking into account the influence of production on degradation degree of machine. Given the complexity of modeling stochastic and constrained optimization problem, analytical studies as well as optimization techniques are used to facilitate resolution of the problem. It consists of transforming it from stochastic to deterministic form and determining its economic solutions. To illustrate the proposed integrated control approach, numerical examples and sensitivity analysis are conducted.