Joint maintenance and production planning optimization model for production systems with operation-dependent failure rate

This paper investigates the issue of integrating production planning and preventive maintenance planning in a batch production context. The production planning problem is a multi-product capacitated lot-sizing problem. The production system is a single machine subject to random failures. To reduce the risk induced by failures, the cyclic preventive maintenance strategy is implemented and minimal repair is carried out at failure. It is assumed that both maintenance actions reduces the production capacity of the system. In the present paper, the failure rate of the system is assumed to be operation-dependent, i.e. the type of item to be processed does affect the production system’s failure rate, which in turn impacts both production and maintenance decisions. The objective is to develop a mathematical programming model to derive an integrated production and maintenance plan that minimizes the expected total costs during a finite planning horizon. An exact solution is derived for a small-size of the formulated problem. To deal with large-size problems, a genetic algorithm is developed as a solution technique. Numerical experiment is then conducted and the obtained results are discussed