Joint maintenance-inventory optimisation of parallel production systems

We model a joint inspection and spare parts inventory policy for maintaining machines in a parallel system, where simultaneous downtime seriously impacts upon production performance and has a significant financial consequence. This dependency between system components means that analysis of realistic maintenance models is intractable. Therefore we use simulation and a numerical optimisation tool to study the cost-optimality of several policies. Inspection maintenance is modelled using the delay-time concept. Critical spare parts replenishment is considered using several variants of a periodic review policy. In particular, our results indicate that the cost-optimal policy is characterised by equal frequencies of inspection and replenishment, and delivery of spare parts that coincides with maintenance intervention. In general, our model provides a framework for studying the interaction of spare parts ordering with maintenance scheduling. The sensitivity analysis that we present offers insights for the effective management of such parallel systems, not only in a paper-making plant, which motivates our modelling development, but also in other manufacturing contexts

Delay-time modelling of a critical system subject to random inspections

We model the inspection-maintenance of a critical system in which the execution of inspections is random. The models we develop are interesting because they mimic realities in which production is prioritised over maintenance, so that inspections might be impeded or they might be opportunistic. Random maintenance has been modelled by others but there is little in the literature that relates to inspection of a critical system. We suppose that the critical system can be good, defective or failed, and that failure impacts on production, so that a failure is immediately revealed, but a defect does not. A defect, if revealed at inspection, is a trigger for replacement. We compare the cost and reliability of random inspections with scheduled periodic inspections and discuss the implications for practice. Our results indicate that inspections that are performed opportunistically rather than scheduled periodically may offer an economic advantage provided opportunities are sufficiently frequent and convenient. A hybrid inspection and replacement policy, with inspections subject to impediments, is robust to departure from its inspection schedule. Keywords: Maintenance; reliability; random inspection; production; qualit

Multi-criteria decision methods to support the maintenance management of complex systems

[ES] Esta tesis doctoral propone el uso de métodos de toma de decisiones multi-criterio (MCDM, por sus iniciales en inglés) como herramienta estratégica para apoyar la gestión del mantenimiento de sistemas complejos. El desarrollo de esta tesis doctoral se enmarca dentro de un acuerdo de cotutela entre la Università degli Studi di Palermo (UNIPA) y la Universitat Politècnica de València (UPV), dentro de sus respectivos programas de doctorado en 'Ingeniería de Innovación Tecnológica' y 'Matemáticas'. Estos programas están estrechamente vinculados a través del tópico MCDM, ya que proporciona herramientas cruciales para gestionar el mantenimiento de sistemas complejos reales utilizando análisis matemáticos serios. El propósito de esta sinergia es tener en cuenta de forma sólida la incertidumbre al atribuir evaluaciones subjetivas, recopilar y sintetizar juicios atribuidos por varios responsables de la toma de decisiones, y tratar con conjuntos grandes de esos elementos. El tema principal del presente trabajo de doctorado es el gestionamiento de las actividades de mantenimiento para aumentar los niveles de innovación tecnológica y el rendimiento de los sistemas complejos. Cualquier sistema puede ser considerado objeto de estudio, incluidos los sistemas de producción y los de prestación de servicios, entre otros, mediante la evaluación de sus contextos reales. Esta tesis doctoral propone afrontar la gestión del mantenimiento a través del desarrollo de tres líneas principales de investigación estrechamente vinculadas. ¿ La primera es el núcleo, e ilustra la mayoría de los aspectos metodológicos de la tesis. Se refiere al uso de métodos MCDM para apoyar decisiones estratégicas de mantenimiento, y para hacer frente a la incertidumbre que afecta a los datos/evaluaciones, incluso cuando están involucrados varios responsables (expertos en mantenimiento) en la toma de decisiones. ¿ La segunda línea desarrolla análisis de fiabilidad para sistemas complejos reales (también en términos de fiabilidad humana) sobre cuya base se debe implementar cualquier actividad de mantenimiento. Estos análisis consideran la configuración de fiabilidad de los componentes del sistema en estudio y las características específicas del entorno operativo. ¿ La tercera línea de investigación aborda aspectos metodológicos importantes de la gestión de mantenimiento y enfatiza la necesidad de monitorizar el funcionamiento de las actividades de mantenimiento y de evaluar su efectividad utilizando indicadores adecuados. Se ha elaborado una amplia gama de casos de estudio del mundo real para evaluar la eficacia de los métodos MCDM en el mantenimiento y así probar la utilidad del enfoque propuesto.[CA] Aquesta tesi doctoral proposa l'ús de mètodes de presa de decisions multi-criteri (MCDM, per les seves inicials en anglès) com a eina estratègica per donar suport a la gestió del manteniment de sistemes complexos. El desenvolupament d'aquesta tesi doctoral s'emmarca dins d'un acord de cotutela entre la Università degli Studi di Palermo (UNIPA) i la Universitat Politècnica de València (UPV), dins dels seus respectius programes de doctorat en 'Enginyeria d'Innovació Tecnològica' i ' Matemàtiques '. Aquests programes estan estretament vinculats a través del tòpic MCDM, ja que proporciona eines crucials per gestionar el manteniment de sistemes complexos reals utilitzant anàlisis matemàtics profunds. El propòsit d'aquesta sinergia és tenir en compte de forma sòlida la incertesa en atribuir avaluacions subjectius, recopilar i sintetitzar judicis atribuïts per diversos responsables de la presa de decisions, i tractar amb conjunts grans d'aquests elements en els problemes plantejats. El tema principal del present treball de doctorat es la gestió de les activitats de manteniment per augmentar els nivells d'innovació tecnològica i el rendiment dels sistemes complexos. Qualsevol sistema pot ser considerat objecte d'estudi, inclosos els sistemes de producció i els de prestació de serveis, entre d'altres, mitjançant l'avaluació dels seus contextos reals. Aquesta tesi doctoral proposa afrontar la gestió del manteniment mitjançant el desenvolupament de tres línies principals d'investigació estretament vinculades. ¿ La primera és el nucli, i il·lustra la majoria dels aspectes metodològics de la tesi. Es refereix a l'ús de mètodes MCDM per donar suport a decisions estratègiques de manteniment, i per fer front a la incertesa que afecta les dades/avaluacions, fins i tot quan estan involucrats diversos responsables (experts en manteniment) en la presa de decisions. ¿ La segona línia desenvolupa anàlisis de fiabilitat per a sistemes complexos reals (també en termes de fiabilitat humana) sobre la qual base s'ha d'implementar qualsevol activitat de manteniment. Aquestes anàlisis consideren la configuració de fiabilitat dels components del sistema en estudi i les característiques específiques de l'entorn operatiu. ¿ La tercera línia d'investigació aborda aspectes metodològics importants de la gestió de manteniment i emfatitza la necessitat de monitoritzar el funcionament de les activitats de manteniment i d'avaluar la seva efectivitat utilitzant indicadors adequats. S'ha elaborat una àmplia gamma de casos d'estudi del món real per avaluar l'eficàcia dels mètodes MCDM en el manteniment i així provar la utilitat de l'enfocament proposat.[EN] This doctoral thesis proposes using multi-criteria decision making (MCDM) methods as a strategic tool to support maintenance management of complex systems. The development of this doctoral thesis is framed within a cotutelle (co-tutoring) agreement between the Università degli Studi di Palermo (UNIPA) and the Universitat Politècnica de València (UPV), within their respective programmes of doctorates in 'Technological Innovation Engineering' and 'Mathematics'. Regarding this thesis, these programmes are closely linked through the topic of MCDM, providing crucial tools to manage maintenance of real complex systems by applying in-depth mathematical analyses. The purpose of this connection is to robustly take into account uncertainty in attributing subjective evaluations, collecting and synthetizing judgments attributed by various decision makers, and dealing with large sets of elements characterising the faced issue. The main topic of the present doctoral work is the management of maintenance activities to increase the levels of technological innovation and performance of the analysed complex systems. All kinds of systems can be considered as objects of study, including production systems and service delivery systems, among others, by evaluating their real contexts. Thus, this doctoral thesis proposes facing maintenance management through the development of three tightly linked main research lines. ¿ The first is the core and illustrates most of the methodological aspects of the thesis. It refers to the use of MCDM methods for supporting strategic maintenance decisions, and dealing with uncertainty affecting data/evaluations even when several decision makers are involved (experts in maintenance). ¿ The second line develops reliability analyses for real complex systems (also in terms of human reliability analysis) on the basis of which any maintenance activity must be implemented. These analyses are approached by considering the reliability configuration of both the components belonging to the system under study and the specific features of the operational environment. ¿ The third research line focuses on important methodological aspects to support maintenance management, and emphasises the need to monitor the performance of maintenance activities and evaluate their effectiveness using suitable indicators. A wide range of real real-world case studies has been faced to evaluate the effectiveness of MCDM methods in maintenance and then prove the usefulness of the proposed approach.Carpitella, S. (2019). Multi-criteria decision methods to support the maintenance management of complex systems [Tesis doctoral no publicada]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/11911

Modelling and simulation for the joint optimisation of inspection maintenance and spare parts inventory in multi-line production settings

A simulation methodology is developed to model the joint optimisation of preventive maintenance and spare parts inventory in multi-line settings. The multi-line machines are subject to failure, based on the delay-time concept, and a selection of policies are used for the replenishment of the machines’ critical component. Production lines of varied configurations are modelled and described in three principal chapters. Firstly, the optimisation of preventive maintenance for a multi-line production system is developed in the context of a case study. The policy proposed indicates that consecutive inspection with priority for failure repair is cost-optimal, which suggests a substantial maintenance cost reduction of 61% compared to the run-to-failure policy. The contribution of this study is first and foremost in narrowing the gap between the theory and practice of managing multi-line systems, and in particular, that the scenarios and policies considered have important economic and engineering implications. In a second study, spare parts provisioning for a single-line system is considered, given that the demand for industrial plant spare parts should be driven, at least in part, by maintenance requirements. A paper-making plant provides a real context, for which simulation models are developed to jointly optimise the planned maintenance and the associated spare part inventory. This challenge is addressed in the context of the failure of parts in service and the replacement of defective parts at inspections of period T, using the delay-time concept, and a selection of replenishment policies. The results indicate that a periodic review policy with replenishment twice as frequent as inspection is cost-optimal. Further discussions and sensitivity analysis give insights into the characteristics and features of the policies considered. Finally, in the third study, the joint optimisation of preventive maintenance and the associated spare parts inventory for a multi-line system is developed using an idealised context. It is found that a review policy with inspection as frequent as replenishment using just-in-time (JIT) ordering is cost-optimal, and also the lowest risk policy; it is associated with the lowest simultaneous machine downtime and low stock-out cost-rates. This is a significant contribution to the literature. An implication of the proposed methodology is that, where mathematical modelling is intractable, or the use of certain assumptions make them less practical, simulation modelling is an appropriate solution tool. Throughout this thesis, the long-run average cost per unit time or cost-rate is used as the optimality criterion. In other contexts, one may wish to use availability or reliability instead. To do so would not change the methodology that is presented here