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

A survey of the machine interference problem

This paper surveys the research published on the machine interference problem since the 1985 review by Stecke & Aronson. After introducing the basic model, we discuss the literature along several dimensions. We then note how research has evolved since the 1985 review, including a trend towards the modelling of stochastic (rather than deterministic) systems and the corresponding use of more advanced queuing methods for analysis. We conclude with some suggestions for areas holding particular promise for future studies.Natural Sciences and Engineering Research Council (NSERC) Discovery Grant 238294-200

An Overview on Application of Machine Learning Techniques in Optical Networks

Today's telecommunication networks have become sources of enormous amounts of widely heterogeneous data. This information can be retrieved from network traffic traces, network alarms, signal quality indicators, users' behavioral data, etc. Advanced mathematical tools are required to extract meaningful information from these data and take decisions pertaining to the proper functioning of the networks from the network-generated data. Among these mathematical tools, Machine Learning (ML) is regarded as one of the most promising methodological approaches to perform network-data analysis and enable automated network self-configuration and fault management. The adoption of ML techniques in the field of optical communication networks is motivated by the unprecedented growth of network complexity faced by optical networks in the last few years. Such complexity increase is due to the introduction of a huge number of adjustable and interdependent system parameters (e.g., routing configurations, modulation format, symbol rate, coding schemes, etc.) that are enabled by the usage of coherent transmission/reception technologies, advanced digital signal processing and compensation of nonlinear effects in optical fiber propagation. In this paper we provide an overview of the application of ML to optical communications and networking. We classify and survey relevant literature dealing with the topic, and we also provide an introductory tutorial on ML for researchers and practitioners interested in this field. Although a good number of research papers have recently appeared, the application of ML to optical networks is still in its infancy: to stimulate further work in this area, we conclude the paper proposing new possible research directions

Cloud computing resource scheduling and a survey of its evolutionary approaches

A disruptive technology fundamentally transforming the way that computing services are delivered, cloud computing offers information and communication technology users a new dimension of convenience of resources, as services via the Internet. Because cloud provides a finite pool of virtualized on-demand resources, optimally scheduling them has become an essential and rewarding topic, where a trend of using Evolutionary Computation (EC) algorithms is emerging rapidly. Through analyzing the cloud computing architecture, this survey first presents taxonomy at two levels of scheduling cloud resources. It then paints a landscape of the scheduling problem and solutions. According to the taxonomy, a comprehensive survey of state-of-the-art approaches is presented systematically. Looking forward, challenges and potential future research directions are investigated and invited, including real-time scheduling, adaptive dynamic scheduling, large-scale scheduling, multiobjective scheduling, and distributed and parallel scheduling. At the dawn of Industry 4.0, cloud computing scheduling for cyber-physical integration with the presence of big data is also discussed. Research in this area is only in its infancy, but with the rapid fusion of information and data technology, more exciting and agenda-setting topics are likely to emerge on the horizon

Modelo de apoio à decisão para a manutenção condicionada de equipamentos produtivos

Doctoral Thesis for PhD degree in Industrial and Systems EngineeringIntroduction: This thesis describes a methodology to combine Bayesian control chart and CBM (Condition-Based Maintenance) for developing a new integrated model. In maintenance management, it is a challenging task for decision-maker to conduct an appropriate and accurate decision. Proper and well-performed CBM models are beneficial for maintenance decision making. The integration of Bayesian control chart and CBM is considered as an intelligent model and a suitable strategy for forecasting items failures as well as allow providing an effectiveness maintenance cost. CBM models provides lower inventory costs for spare parts, reduces unplanned outage, and minimize the risk of catastrophic failure, avoiding high penalties associated with losses of production or delays, increasing availability. However, CBM models need new aspects and the integration of new type of information in maintenance modeling that can improve the results. Objective: The thesis aims to develop a new methodology based on Bayesian control chart for predicting failures of item incorporating simultaneously two types of data: key quality control measurement and equipment condition parameters. In other words, the project research questions are directed to give the lower maintenance costs for real process control. Method: The mathematical approach carried out in this study for developing an optimal Condition Based Maintenance policy included the Weibull analysis for verifying the Markov property, Delay time concept used for deterioration modeling and PSO and Monte Carlo simulation. These models are used for finding the upper control limit and the interval monitoring that minimizes the (maintenance) cost function. Result: The main contribution of this thesis is that the proposed model performs better than previous models in which the hypothesis of using simultaneously data about condition equipment parameters and quality control measurements improve the effectiveness of integrated model Bayesian control chart for Condition Based Maintenance.Introdução: Esta tese descreve uma metodologia para combinar Bayesian control chart e CBM (Condition- Based Maintenance) para desenvolver um novo modelo integrado. Na gestão da manutenção, é importante que o decisor possa tomar decisões apropriadas e corretas. Modelos CBM bem concebidos serão muito benéficos nas tomadas de decisão sobre manutenção. A integração dos gráficos de controlo Bayesian e CBM é considerada um modelo inteligente e uma estratégica adequada para prever as falhas de componentes bem como produzir um controlo de custos de manutenção. Os modelos CBM conseguem definir custos de inventário mais baixos para as partes de substituição, reduzem interrupções não planeadas e minimizam o risco de falhas catastróficas, evitando elevadas penalizações associadas a perdas de produção ou atrasos, aumentando a disponibilidade. Contudo, os modelos CBM precisam de alterações e a integração de novos tipos de informação na modelação de manutenção que permitam melhorar os resultados.Objetivos: Esta tese pretende desenvolver uma nova metodologia baseada Bayesian control chart para prever as falhas de partes, incorporando dois tipos de dados: medições-chave de controlo de qualidade e parâmetros de condição do equipamento. Por outras palavras, as questões de investigação são direcionadas para diminuir custos de manutenção no processo de controlo.Métodos: Os modelos matemáticos implementados neste estudo para desenvolver uma política ótima de CBM incluíram a análise de Weibull para verificação da propriedade de Markov, conceito de atraso de tempo para a modelação da deterioração, PSO e simulação de Monte Carlo. Estes modelos são usados para encontrar o limite superior de controlo e o intervalo de monotorização para minimizar a função de custos de manutenção.Resultados: A principal contribuição desta tese é que o modelo proposto melhora os resultados dos modelos anteriores, baseando-se na hipótese de que, usando simultaneamente dados dos parâmetros dos equipamentos e medições de controlo de qualidade. Assim obtém-se uma melhoria a eficácia do modelo integrado de Bayesian control chart para a manutenção condicionada

Quantitative methods for data driven reliability optimization of engineered systems

Particle accelerators, such as the Large Hadron Collider at CERN, are among the largest and most complex engineered systems to date. Future generations of particle accelerators are expected to increase in size, complexity, and cost. Among the many obstacles, this introduces unprecedented reliability challenges and requires new reliability optimization approaches. With the increasing level of digitalization of technical infrastructures, the rate and granularity of operational data collection is rapidly growing. These data contain valuable information for system reliability optimization, which can be extracted and processed with data-science methods and algorithms. However, many existing data-driven reliability optimization methods fail to exploit these data, because they make too simplistic assumptions of the system behavior, do not consider organizational contexts for cost-effectiveness, and build on specific monitoring data, which are too expensive to record. To address these limitations in realistic scenarios, a tailored methodology based on CRISP-DM (CRoss-Industry Standard Process for Data Mining) is proposed to develop data-driven reliability optimization methods. For three realistic scenarios, the developed methods use the available operational data to learn interpretable or explainable failure models that allow to derive permanent and generally applicable reliability improvements: Firstly, novel explainable deep learning methods predict future alarms accurately from few logged alarm examples and support root-cause identification. Secondly, novel parametric reliability models allow to include expert knowledge for an improved quantification of failure behavior for a fleet of systems with heterogeneous operating conditions and derive optimal operational strategies for novel usage scenarios. Thirdly, Bayesian models trained on data from a range of comparable systems predict field reliability accurately and reveal non-technical factors' influence on reliability. An evaluation of the methods applied to the three scenarios confirms that the tailored CRISP-DM methodology advances the state-of-the-art in data-driven reliability optimization to overcome many existing limitations. However, the quality of the collected operational data remains crucial for the success of such approaches. Hence, adaptations of routine data collection procedures are suggested to enhance data quality and to increase the success rate of reliability optimization projects. With the developed methods and findings, future generations of particle accelerators can be constructed and operated cost-effectively, ensuring high levels of reliability despite growing system complexity