Modelling and simulation for the joint maintenance-inventory optimisation of production systems

Simulation methodologies are developed to model the joint optimization of preventive maintenance and spare parts inventory for a specific industrial plant under different production configurations. First, spare parts provisioning for a single-line system is considered, with the assumption that the demand is driven by maintenance requirements. The results indicate that a periodic review policy with replenishment as frequent as inspection is cost-optimal. Second, the joint optimization model for a multi-line (parallel) system is developed. It is found that a just-in-time review policy with inspection as frequent as replenishment produces the lowest cost policy. In this latter case, an implication of the proposed methodology is that, where mathematical modelling is intractable, or the use of certain assumptions make them impractical, simulation modelling is an appropriate solution tool. Under both production settings, the long-run average cost per unit time is used as the optimality criterion for the comparison of several policies

Joint optimisation of inspection maintenance and spare parts provisioning: a comparative study of inventory policies using simulation and survey data

The demand for industrial plant spare parts is driven, at least in part, by maintenance requirements. It is therefore important to jointly optimise planned maintenance and the associated spare parts inventory using the most appropriate maintenance and replenishment policies. In this simulation-based study, we address this challenge in the context of the random failure of parts in service and the replacement of defective parts at inspections of period T. Inspections are modelled using the delay-time concept. A number of simultaneous periodic review and continuous review replenishment policies are compared. A paper making plant provides a real context for the presentation of our ideas. We survey practitioners working with such plant to collect real data that inform the values of parameters in the models. Our simulation results indicate that a periodic review policy with ordering that is twice as frequent as inspection is cost optimal in the context of the plant that we study. For the purpose of comparison, we also present and discuss the characteristics of the various policies considered

Optimisation of inspection policy for multi-line production systems

This paper develops a simulation model to determine the cost-optimum inspection policy for a multi-line production system taking account of simultaneous downtime. The machines in the multi-line system are subject to a two stage failure process that is modelled using the delay-time concept. Our study indicates that: consecutive inspection of lines with priority for failure repair is cost-optimal, with a cost reduction of 61% compared to a ‘run-to-failure’ policy; and maintainers need to be responsive to operational requirements. Our ideas are developed in the context of a case study of a plant with three parallel lines, one of which is on cold-standby. Keywords: maintenance; delay-time model; simulation; production; parallel lines; manufacturing; preventive maintenance

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

Pre-storage putrescine treatment maintains quality and prolongs postharvest life of Musa acuminata L.

The study was carried out to determine the effect of putrescine on quality and postharvest life of Musa acuminata L. during storage. The fruits were dipped at different concentrations of putrescine (0.5, 1 and 2 mM for 30 min) and distilled water as ‘control’. Changes in fruit quality attributes such as weight loss, firmness, skin color (L*, hue angle), total soluble solids (TSS), titratable acidity (TA), pH, ascorbic acid, polyphenol oxidase (PPO) and polygalacturonase (PG) enzymatic activity were calculated at harvest and after 5, 10, 15 and 20 days of storage at 0±1°C, 80-85% relative humidity. Weight loss, fruit softening, skin color changes, TSS, pH, the activity of PPO and PG increased during fruit ripening but the rate of changes was significantly slowed in putrescine treated fruits. Moreover, putrescine application maintained higher levels of TA, ascorbic acid and reduced the loss of sensory acceptability and decay incidence compared to control. In conclusion, the postharvest dip treatment of putrescine could be an effective means for extending the storage life of Musa acuminata L

Effect of zinc foliar application on auxin and gibberellin hormones and catalase and superoxide dismutase enzyme activity of corn (Zea mays L) under water stress

To study the effects of zinc foliar application and water stress on quantitative and qualitative characteristics of corn, an experiment was conducted in Varamin, Iran during the growing season of 2011. The experimental design was randomized complete blocks in factorial arrangement with four replications. Factors included water stress (complete irrigation, irrigation after 90 mm of water evaporation and irrigation after 130 mm of water evaporation from class A pan) and the zinc foliar applications were as follows: 0, zinc sulfate and zinc chelate. Result showed that severe water stress decreased seed yield, oil percentage, chlorophyll content, relative water content, zinc grain content, auxin and gibberellin, and it caused an increase in antioxidant enzyme activity. Zinc foliar application increased all tested attributes under severe water stress. The results of these tests showed that zinc foliar application was effective against the detrimental effects of water stress

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

Isolation of probiotic bacteria from raw camel's milk and their antagonistic effects on two bacteria causing food poisoning

Lactic acid bacteria (LAB) is one of the main classes of acid-producing organisms in the food industry, and they play a vital part in many food and feed fermentations. We isolated and performed molecular identification of LAB from raw camel's milk and assessed their protective effects against pathogenicity induced by Staphylococcus aureus and Escherichia coli. Fourteen samples of camel's milk were obtained from several districts under aseptic conditions. Bacteria isolation was performed by plating the samples on selective media. Isolates were identified by amplification of the 16S ribosomal RNA by PCR and sequencing. A total of 32 isolates were randomly picked, eight of which were analysed in this study. On the basis of phenotypic and genotypic methods, isolated LAB was included Leuconostoc mesenteroides, Lactobacillus plantarum, Weissella paramesenteroides and Weissella confuse. Antagonistic activity of isolated LAB against two pathogenic bacteria showed that they had more inhibitory activity against S. aureus subsp. aureus PTCC 1431 than E. coli ATCC 25922. This study discovered that raw camel's milk obtained from three districts of Kerman province contain LAB bacteria that have antagonistic properties on S. aureus. © 2018 The Author