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

Some improvements on adaptive genetic algorithms for reliability-related applications

Reliability Engineering and System Safety952120-126RESS

Algoritmo genético adaptativo para otimização de modelos de simulação a eventos discretos.

Métodos de otimização combinados à simulação a eventos discretos têm sido utilizados nas mais diversas aplicações. Entretanto, estes métodos possuem baixo desempenho em relação ao tempo computacional, ao manipularem mais de uma variável de decisão. Dessa forma, o objetivo deste trabalho é desenvolver um algoritmo genético adaptativo para otimização não linear de modelos de simulação, capaz de atingir bons resultados em termos de eficiência e qualidade de resposta, quando comparado a uma ferramenta de otimização comercial. Para tal, foi utilizado o delineamento de experimentos para definir os parâmetros mais significativos do algoritmo genético, e, para estes parâmetros, foram propostas adaptações. Pôde-se verificar que os parâmetros tamanho de população e número de gerações foram os mais significativos. Desta forma, estratégias adaptativas foram propostas a estes parâmetros, focando principalmente a definição do tamanho da população inicial e seu incremento ao longo das iterações realizadas pelo algoritmo de otimização. Foi implementado também um critério de parada para o algoritmo, baseado na melhoria da qualidade das soluções ao longo das gerações, e dois conjuntos de parâmetros foram definidos para os operadores genéticos de crossover e mutação. As alterações introduzidas no algoritmo fizeram com que este conseguisse apresentar bons resultados, tanto em termos de qualidade de resposta, quanto em termos de tempo necessário para sua convergência, quando comparado aos resultados alcançados por um software comercial na otimização de oito objetos de estudo

Optimal Burn-In under Complex Failure Processes: Some New Perspectives

Ph.DDOCTOR OF PHILOSOPH

Software reliability modeling and release time determination

Ph.DDOCTOR OF PHILOSOPH

Structural optimization using evolutionary multimodal and bilevel optimization techniques

This research aims to investigate the multimodal properties of structural optimization using techniques from the field of evolutionary computation, specifically niching and bilevel techniques. Truss design is a well-known structural optimization problem which has important practical applications in many fields. Truss design problems are typically multimodal by nature, meaning that it offers multiple equally good design solutions with respect to the topology and/or sizes of the members, but they are evaluated to have similar or equally good objective function values. From a practical standpoint, it is desirable to find as many alternative designs as possible, rather than finding a single design, as often practiced. Niching is an intuitive way of finding multiple optimal solutions in a single optimization run. Literature shows that existing niching methods are largely designed for handling continuous optimization problems. There does not exist a well-studied niching method for constrained discrete optimization problems like truss design problems. In addition, there are no well-defined multimodal discrete benchmark problems that can be used to evaluate the reliability and robustness of such a niching method. This thesis fills the identified research gaps by means of five major contributions. In the first contribution, we design a test suite for producing a diverse set of challenging multimodal discrete benchmark problems, which can be used for evaluating the discrete niching methods. In the second contribution, we develop a binary speciation-based PSO (B-SPSO) niching method using the concept of speciation in nature along with the binary PSO (BPSO). The results show that the proposed multimodal discrete benchmark problems are useful for the evaluation of the discrete niching methods like B-SPSO. In light of this study, a time-varying transfer function based binary PSO (TVT-BPSO) is developed for the B-SPSO which is the third contribution of this thesis. We propose this TVT-BPSO for maintaining a better balance between exploration/exploitation during the search process of the BPSO. The results show that the TVT-BPSO outperforms the state-of-the-art discrete optimization methods on the large-scale 0-1 knapsack problems. The fourth contribution is to consider and formulate the truss design problem as a bilevel optimization problem. With this new formulation, truss topology can be optimized in the upper level, at the same time the size of that truss topology can be optimized in the lower level. The proposed bilevel formulation is a precursor to the development of a bilevel niching method (Bi-NM) which constitutes the fifth contribution of this thesis. The proposed Bi-NM method performs niching at the upper level and a local search at the lower level to further refine the solutions. Extensive empirical studies are carried out to examine the accuracy, robustness, and efficiency of the proposed bilevel niching method in finding multiple topologies and their size solutions. Our results confirm that the proposed bilevel niching method is superior in all these three aspects over the state-of-the-art methods on several low to high-dimensional truss design problems