Optimization Model for Maintenance Planning of Loading Equipment in Open Pit Mines

Maintenance plays a significant role in operating costs in the mining industry. Improving this matter controls maintenance costs and enhances productivity and production effectively. Shovels are one of the most widely used loading machines in non-continuous activities. Thus, evaluating and optimizing their availability is one of the essential solutions to achieving high productivity and cost reduction. This paper presents a mathematical programming model to maximize availability and minimize the total expected costs. We programmed the proposed nonlinear planning model using the Symbiotic Organisms Search (SOS) meta-heuristic algorithm in Matlab software. It determines the optimal maintenance intervals for different parts of the shovel. The maintenance benefit analysis approach selects various maintenance activities in optimal maintenance intervals. The model is implemented in a practical case study, Chadormalu Iron Mine, to evaluate its performance. The failure distribution matches the Weibull distribution function. The computational results show the efficiency of the presented approach

Preventive maintenance and replacement scheduling : models and algorithms.

Preventive maintenance is a broad term that encompasses a set of activities aimed at improving the overall reliability and availability of a system. Preventive maintenance involves a basic trade-off between the costs of conducting maintenance/replacement activities and the cost savings achieved by reducing the overall rate of occurrence of system failures. Designers of preventive maintenance schedules must weigh these individual costs in an attempt to minimize the overall cost of system operation. They may also be interested in maximizing the system reliability, subject to some sort of budget constraint. In this dissertation, we present a complete discussion about the problem definition and review the literature. We develop new nonlinear mixed-integer optimization models, solve them by standard nonlinear optimization algorithms, and analyze their computational results. In addition, we extend the optimization models by considering engineering economy features and reformulate them as a multi-objective optimization model. We optimize this model by generational and steady state genetic algorithms as well as by a simulated annealing algorithm and demonstrate the computational results obtained by implementation of these algorithms. We perform a sensitivity analysis on the parameters of the optimization models and present a comparison between exact and metaheuristic algorithms in terms of computational efficiency and accuracy. Finally, we present a new mathematical function to model age reduction and improvement factor parameter used in optimization models. In addition, we develop a practical procedure to estimate the effect of maintenance activity on failure rate and effective age of multi component systems

Adaptive policy of buffer allocation and preventive maintenance actions in unreliable production lines

Abstract The buffer allocation problem is an NP-hard combinatorial optimization problem, and it is an important design problem in manufacturing systems. The research proposed in this paper concerns a product line consisting of n unreliable machines with n − 1 buffers and a preventive maintenance policy. The focus of the research is to obtain a better trade-off between the buffer level and the preventive maintenance actions. This paper proposes a dynamic control of the buffers' level and the interval between two consecutive preventive actions. The set of the parameter of the proposed policy allows choosing the reduction in the costs or the increment of the throughput rate. A simulation model is developed to test the proposed model to the solution proposed in the literature. The proposed policy leads to better results in terms of total costs reduction keeping high production rate, while the design of a fixed level of buffer works better for lower production rates required

Prognostics-Based Two-Operator Competition for Maintenance and Service Part Logistics

Prognostics and timely maintenance of components are critical to the continuing operation of a system. By implementing prognostics, it is possible for the operator to maintain the system in the right place at the right time. However, the complexity in the real world makes near-zero downtime difficult to achieve partly because of a possible shortage of required service parts. This is realistic and quite important in maintenance practice. To coordinate with a prognostics-based maintenance schedule, the operator must decide when to order service parts and how to compete with other operators who also need the same parts. This research addresses a joint decision-making approach that assists two operators in making proactive maintenance decisions and strategically competing for a service part that both operators rely on for their individual operations. To this end, a maintenance policy involving competition in service part procurement is developed based on the Stackelberg game-theoretic model. Variations of the policy are formulated for three different scenarios and solved via either backward induction or genetic algorithm methods. Unlike the first two scenarios, the possibility for either of the operators being the leader in such competitions is considered in the third scenario. A numerical study on wind turbine operation is provided to demonstrate the use of the joint decision-making approach in maintenance and service part logistics

Multi-State System Reliability: A New and Systematic Review

AbstractReliability analysis considering multiple possible states is known as multi-state (MS) reliability analysis. Multi-state system reliability models allow both the system and its components to assume more than two levels of performance. Through multi-state reliability models provide more realistic and more precise representations of engineering systems, they are much more complex and present major difficulties in system definition and performance evaluation. MSS reliability has received a substantial amount of attention in the past four decades. This article presents a new and systematic review about multi-state system reliability. A timely review is an effective work related to improving the development of MSS theory. The review about the latest studies and advances about multi-state system reliability evaluation, multi-state systems optimization and multi-state systems maintenance is summarized in this paper

Integration of production, maintenance and quality : Modelling and solution approaches

Dans cette thèse, nous analysons le problème de l'intégration de la planification de production et de la maintenance préventive, ainsi que l'élaboration du système de contrôle de la qualité. Premièrement, on considère un système de production composé d'une machine et de plusieurs produits dans un contexte incertain, dont les prix et le coût changent d'une période à l'autre. La machine se détériore avec le temps et sa probabilité de défaillance, ainsi que le risque de passage à un état hors contrôle augmentent. Le taux de défaillance dans un état dégradé est plus élevé et donc, des coûts liés à la qualité s’imposent. Lorsque la machine tombe en panne, une maintenance corrective ou une réparation minimale seront initiées pour la remettre en marche sans influer ses conditions ou le processus de détérioration. L'augmentation du nombre de défaillances de la machine se traduit par un temps d'arrêt supérieur et un taux de disponibilité inférieur. D'autre part, la réalisation des plans de production est fortement influencée par la disponibilité et la fiabilité de la machine. Les interactions entre la planification de la maintenance et celle de la production sont incorporées dans notre modèle mathématique. Dans la première étape, l'effet de maintenance sur la qualité est pris en compte. La maintenance préventive est considérée comme imparfaite. La condition de la machine est définie par l’âge actuel, et la machine dispose de plusieurs niveaux de maintenance avec des caractéristiques différentes (coûts, délais d'exécution et impacts sur les conditions du système). La détermination des niveaux de maintenance préventive optimaux conduit à un problème d’optimisation difficile. Un modèle de maximisation du profit est développé, dans lequel la vente des produits conformes et non conformes, les coûts de la production, les stocks tenus, la rupture de stock, la configuration de la machine, la maintenance préventive et corrective, le remplacement de la machine et le coût de la qualité sont considérés dans la fonction de l’objectif. De plus, un système composé de plusieurs machines est étudié. Dans cette extension, les nombres optimaux d’inspections est également considéré. La fonction de l’objectif consiste à minimiser le coût total qui est la somme des coûts liés à la maintenance, la production et la qualité. Ensuite, en tenant compte de la complexité des modèles préposés, nous développons des méthodes de résolution efficaces qui sont fondées sur la combinaison d'algorithmes génétiques avec des méthodes de recherches locales. On présente un algorithme mimétique qui emploi l’algorithme Nelder-Mead, avec un logiciel d'optimisation pour déterminer les valeurs exactes de plusieurs variables de décisions à chaque évaluation. La méthode de résolution proposée est comparée, en termes de temps d’exécution et de qualités des solutions, avec plusieurs méthodes Métaheuristiques. Mots-clés : Planification de la production, Maintenance préventive imparfaite, Inspection, Qualité, Modèles intégrés, MétaheuristiquesIn this thesis, we study the integrated planning of production, maintenance, and quality in multi-product, multi-period imperfect systems. First, we consider a production system composed of one machine and several products in a time-varying context. The machine deteriorates with time and so, the probability of machine failure, or the risk of a shift to an out-of-control state, increases. The defective rate in the shifted state is higher and so, quality related costs will be imposed. When the machine fails, a corrective maintenance or a minimal repair will be initiated to bring the machine in operation without influencing on its conditions or on the deterioration process. Increasing the expected number of machine failures results in a higher downtime and a lower availability rate. On the other hand, realization of the production plans is significantly influenced by the machine availability and reliability. The interactions between maintenance scheduling and production planning are incorporated in the mathematical model. In the first step, the impact of maintenance on the expected quality level is addressed. The maintenance is also imperfect and the machine conditions after maintenance can be anywhere between as-good-as-new and as-bad-as-old situations. Machine conditions are stated by its effective age, and the machine has several maintenance levels with different costs, execution times, and impacts on the system conditions. High level maintenances on the one hand have greater influences on the improvement of the system state and on the other hand, they occupy more the available production time. The optimal determination of such preventive maintenance levels to be performed at each maintenance intrusion is a challenging problem. A profit maximization model is developed, where the sale of conforming and non-conforming products, costs of production, inventory holding, backorder, setup, preventive and corrective maintenance, machine replacement, and the quality cost are addressed in the objective function. Then, a system with multiple machines is taken into account. In this extension, the number of quality inspections is involved in the joint model. The objective function minimizes the total cost which is the sum of maintenance, production and quality costs. In order to reduce the gap between the theory and the application of joint models, and taking into account the complexity of the integrated problems, we have developed an efficient solution method that is based on the combination of genetic algorithms with local search and problem specific methods. The proposed memetic algorithm employs Nelder-Mead algorithm along with an optimization package for exact determination of the values of several decision variables in each chromosome evolution. The method extracts not only the positive knowledge in good solutions, but also the negative knowledge in poor individuals to determine the algorithm transitions. The method is compared in terms of the solution time and quality to several heuristic methods. Keywords : Multi-period production planning, Imperfect preventive maintenance, Inspection, Quality, Integrated model, Metaheuristic

Production Scheduling Requirements to Smart Manufacturing

The production scheduling has attracted a lot of researchers for many years, however most of the approaches are not targeted to deal with real manufacturing environments, and those that are, are very particular for the case study. It is crucial to consider important features related with the factories, such as products and machines characteristics and unexpected disturbances, but also information such as when the parts arrive to the factory and when should be delivered. So, the purpose of this paper is to identify some important characteristics that have been considered independently in a lot of studies and that should be considered together to develop a generic scheduling framework to be used in a real manufacturing environment.authorsversionpublishe

Joint scheduling of jobs and preventive maintenance operations in the flowshop sequencing problem: A resolution with sequential and integrated strategies.

International audienceUsually, scheduling of maintenance operations and production sequencing are dealt with separately in the literature and, therefore, also in the industry. Given that maintenance affects available production time and elapsed production time affects the probability of machine failure, this interdependency seems to be overlooked in the literature. This paper presents a comparative study on joint production and preventive maintenance scheduling strategies regarding flowshop problems. The sequential strategy which consists of two steps: first scheduling the production jobs then inserting maintenance operations, taking the production schedule as a strong constraint. The integrated one which consists of simultaneously scheduling both maintenance and production activities based on a common representation of these two activities. For each strategy, a constructive heuristic and two meta-heuristics are proposed: NEH heuristic, Genetic algorithm and Taboo search. The goal is to optimize an objective function which takes into account both production and maintenance criteria. The proposed heuristics have been applied to non-standard test problems which represent joint production and maintenance benchmark flowshop scheduling problems taken from Benbouzid et al. (2003). A comparison of the solutions yielded by the heuristics developed in this paper with the heuristic solutions given by Taillard (1993) is undertaken with respect to the minimization of performance loss after maintenance insertion. The comparison shows that the proposed integrated GAs are clearly superior to all the analyzed algorithms