Joint optimisation of the maintenance and buffer stock policies considering back orders

Abstract

Inventory control and maintenance systems are two main processes in production systems that play a vital role in the efficiency of production resources. This study aims to propose a joint optimisation procedure for maintenance and inventory policies in a single-machine production system considering back orders. The failure rate is random and the minimum level of accessibility required for preventive maintenance is considered. To close the problem at hand to the real-world condition, demand is considered as uncertain and shortage is inevitable. In addition, the unsatisfied demand is considered as back order. The problem is described and formulated via a mathematical model and all the possible scenarios corresponding to the different possible cases of the problem are described. Then a numerical iterative procedure is introduced to solve the problem in a reasonable time. The proposed procedure does not explore all solution space, but it behaves like a numerical optimisation procedure and provides a near optimal solution. The performance of the proposed method is evaluated using a numerical instance based on a real case study. In addition, some sensitivity analyses are performed to identify the most important effective parameters.

KEYWORDS:

• Joint optimisation
• preventive maintenance
• corrective maintenance
• inventory control
• back order

Disclosure statement

No potential conflict of interest was reported by the author(s).

Data availability statement

The authors confirm that the data supporting the findings of this study are available within the article.

Additional information

Funding

No funding is received by this study.

Notes on contributors

Sahra Sheydaei Aghdam

Sahra Sheydaei Aghdam is a graduate student of the Al-Zahra University with a master's degree in industrial engineering. Her masters' thesis concentrates on Joint optimization of maintenance, production and inventory policies with back order in a single machine. She is interested in doing research on Stochastic Programming, Mathematical programming, Machine learning, etc. She is currently working in a private manufacturing company in the field of production planning and supply chain. The things she does in the company are: Purchase planning and controlling, optimal planning of orders (EOQ, Material ordering), inventory control and determine the point of orders, follow up of raw materials until it reaches the warehouse and MRP plan.

Parviz Fattahi

Parviz Fattahi is currently Full Professor at the Department of Industrial Engineering, Colleague of Engineering at Al-Zahra University. He holds his BS, MS, and PhD degrees in Industrial Engineering from Iran University of Science and Technology. His research interests include optimization in production planning, scheduling, and supply chain management. He also served as Associate Professor at the Department of Industrial Engineering in Bu-Ali Sina University from 2001 to 2011. He has published over 100 papers in international journals such as: Journal of intelligent manufacturing, the International Journal of Advanced Manufacturing technology, CIRP Journal of Manufacturing Science and Technology, Applied Mathematical Modelling, Water resources management, Applied Soft Computing, International Journal of Production Research, Journal of Manufacturing Systems, International Journal of Computer Integrated Manufacturing, and Computers & Operations Research. My Google Scholar address is: https://scholar.google.co.in/citations?user=WehwoJ0AAAAJ&hl=en

Seyed Mohammad Hassan Hosseini

Dr. Seyed Mohammad Hassan Hosseini is currently associate professor of Industrial Engineering College at Shahrood University of Technology, where he has been since 21013. He received a B.S. from Iran University of Science and Technology in 2000, and an M.S. from the Amirkabir University of Technology. He received his Ph.D. in Industrial Engineering from the Payam-e-Noor University of Tehran in 2012. He served at the department of quality assurance and customer satisfaction of Iran Khodro Company (IKCO) as the most famous car manufactures in Middle East from 2002 to 2012. His main areas of research are the modelling of scheduling (especially flow shop) and production planning and control, quality engineering and management, and decision making techniques. He has published over than 50 papers in Journal of applied mathematical modelling, The International Journal of Advanced Manufacturing Technology, International Journal of Industrial Engineering Computations, Computers & Operations Research (COR), Soft Computing, System Science, International Journal of Supply and Operations Management, Journal of Optimization in Industrial Engineering, Journal of Industrial and Systems Engineering, Journal of applied mathematics and computations, Environment Systems and Decisions, International Journal of Productivity and Quality Management etc. As of 2014, Google Scholar reports over than 500 citations to his work. He has given numerous invited talks and tutorials, and is a founder of and consultant to companies involved in car making. His Google Scholar address is: https://scholar.google.com/citations?user=l07MYTkAAAAJ&hl=en

Samaneh Babaeimorad

Samane Babaeimorad is currently Ph.D. student of Industrial Engineering College at Alzahra University of Iran. She received a M.S. from Kharazmi University of Iran in 2015. Her main field of activity is scheduling, maintenance, and quality control. The topic of her Ph.D. thesis is to present a model for scheduling a production system, taking into account maintenance and quality control in industry. She has published a number of articles on optimization in industrial engineering journals. She is interested in multiple criteria decision analysis, linear programming, machine learning, and optimization methods. Her Google Scholar address is: https://scholar.google.com/citations?user=WV8Y-lIAAAAJ&hl=fa

Shib Sankar Sana

Dr Shib Sankar Sana is currently Principal of Kishore Bharati Bhagini Nivedita College under the University of Calcutta. He served at the Department of Mathematics as Associate Professor in Bhangar Mahavidyalaya from 2001 to 2018 and Department of Applied Mathematics, Birla Institute of Technology, Mesra, Ranchi as an Associate Lecturer during 1999-2001. His main areas of research are the modelling of production planning and inventory control, Biomathematics and Soft Computing. He has published over 210 papers in Journal of Cleaner Production, European Journal of Operational Research, International Journal of Retailing and Consumer Services, International Journal of Production Economics, Computers and Mathematics with Application, Mathematical and Computer Modelling, Applied Mathematics and Computation, Journal of Modelling in Management, American Journal of Mathematical and Management Sciences, International Journal of Systems Science, International Journal of Systems Science: Operations & Logistics, Far East Journal of Applied Mathematics, Nonlinear Phenomena in Complex Systems, Advanced Modeling and Optimization, Vietnam Journal of Mathematics, Yugoslav Journal of Operational Research, International Journal of Operational Research, International Journal of Services Operations Management, International Journal of Modeling, Identification and Control, International Journal of Innovative Computing and Application, International Journal of Procurement Management, International Journal of Mathematics and Operations Research, IMA Journal of Management Mathematics, International Journal of Information and Decision Science, International Journal of Management Science and Engineering Management, Applied Mathematical Modelling, Decision Support Systems, Service Science, Review in Aquaculture, International Journal of Production Research, Expert Systems with Application, Economic Modelling, Journal of Manufacturing Systems, Journal of Advanced Manufacturing Systems, Journal of Industrial & Management Optimization, Annals of Operations Research, International Journal of Logistics Research and Applications, Computers & Industrial Engineering, Journal of Intelligent Manufacturing, International Journal of Applied and Computational Mathematics, RAIRO-Operations Research, CIRP Journal of Manufacturing Science and Technology, Control and Cybernetics, Cybernetics and Systems, etc. He is a member of the editorial board of International Journal of Systems Science: Operations & Logistics, International Journal of Management Science and Engineering Management, American Journal of Computational and Applied Mathematics, Universal Journal of Applied Mathematics, International Journal of Advanced Mathematics, American Journal of Industrial and Business Management, Operations Research and Applications: An International Journal of Applied Management Science, etc. My Google Scholar address is : https://scholar.google.co.in/citations?user=WehwoJ0AAAAJ&hl=en