A joint model of production scheduling and predictive

ORIGINAL ARTICLE

A joint model of production scheduling and predictive maintenance for minimizing job tardiness

Ershun Pan &Wenzhu Liao &Lifeng Xi

Received:15July 2010/Accepted:15September 2011/Published online:4October 2011#Springer-Verlag London Limited 2011

Abstract As increasingly diverse tasks are being processed on single multi-functional machine,production scheduling has become a critical issue in the planning and management of manufacturing processes.However,the majority of produc-tion scheduling literature ignores machine availability and assumes that machine is available all the time.In reality,machines physically deteriorate with increased usage and time.Thus,there is an intense need for manufacturing industries to reduce unexpected breakdowns and remain competitive,and motivating maintenance operations should be integrated into production scheduling models.With the advancements in sensor and prognostic technologies,machine ’s condition can be monitored and assessed over time through conducting predictive maintenance.Hence,based on this scheme,this study proposes a single-machine-based scheduling model incorporating production scheduling and predictive maintenance.A machine ’s effective age and remaining maintenance life are introduced to describe machine degradation.Finally,a numerical example is given;the computational results show that this integrated schedul-ing model has better performance than those existing models,which proves its efficiency.

Keywords Production scheduling .Predictive

maintenance .Health index (HI).Effective age .Remaining maintenance life (RML).Tardiness

1Introduction

In today ’s competitive market,different kinds of single machine have been designed to be able to process various products (e.g.,intelligent machine tool)and conduct diverse tasks.Hence,how to effectively arrange the sequence of tasks for a given single machine,that is production scheduling,has become a critical issue in the planning and management of manufacturing processes.As an important component of manufacturing industry,production scheduling has been widely studied and various determin-istic optimization models have been developed to maximize some measures of customer satisfaction [1].In manufactur-ing industry,production scheduling can have a major impact on the productivity of a process,it can minimize the production time and the cost by determining what to make and when to make for a production facility [2].Overall,production scheduling aims to maximize the efficiency of a given operation and ultimately reduce costs.Since the 1950s,many production scheduling models for single-machine problem,flow and job shop problem,and capacitated lot-sizing problem have been developed [3–6].And single-machine problem has been most studied among all the scheduling problems.The best research existing for a vast set of problem specifications are the procedures for minimizing the mean flow time,the maximum tardiness,and the number of late tasks.All of these procedures seek to determine the optimal task sequence based on different objectives.Based on the single-machine prob-lem,other kinds of problems such as parallel machines problem or flow shop problems are studied (discussed in Refs.[7–9]).

Although the previous theoretical production scheduling models studied how to make a good task schedule,they usually do not take machine availability constraints into

E.Pan (*):L.Xi

Department of Industrial Engineering and Logistics Management,Shanghai Jiao Tong University,

Shanghai 200240,People ’s Republic of China e-mail:pes@cee02d639b6648d7c1c74632

W.Liao

Department of Industrial Engineering,Chongqing University,Chongqing 400030,People ’s Republic of China

Int J Adv Manuf Technol (2012)60:1049–1061DOI 10.1007/s00170-011-3652-4

account and assume machines are always available for processing the tasks during the planning time horizon,yet this assumption is inappropriate in many real-world scheduling cases[5,10].In reality,machine breakdown is common after long-time operation,hence,the machine will be unavailable while processing tasks due to its failures [11].Since machine breakdown will reduce production efficiency,maintenance as an important part in manufac-turing systems is used to keep machines in good condition to decrease failures,which makes maintenance planning become more and more important in manufacturing processes.Hence,maintenance should be considered as a part of production scheduling models so that the availability of a machine is known as opposed to assumed,resulting in more robust production schedules.Like machine break-downs,when performing maintenance operations,the tasks being processed must be stopped.The machine will be unavailable when an accidental breakdown or a mainte-nance operation occurs.Thus,a good maintenance planning should be considered to make production scheduling model more realistic.As machine breakdown is stochastic and maintenance is deterministic,maintenance planning can be treated as availability constraint in a production scheduling model.

As production scheduling models with the consideration of maintenance operations arouse great interest of research-ers,the machine availability problem for production scheduling models has been widely discussed in the past decades.However,those production scheduling models with maintenance planning usually do not consider machine degradation.Most of them just pre-design a fixed mainte-nance interval and arrange job sequences based on this maintenance interval,which cannot show maintenance operation’s real influence on production scheduling model. The related literature review is given below in Section2. Hence,in order to describe the interaction between production scheduling and maintenance planning,this study is devoted to propose an integrated scheduling model by incorporating production scheduling …… 此处隐藏：48105字，全部文档内容请下载后查看。喜欢就下载吧 ……