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A Mathematical Model: A Flexible Manufacturing System, Prone to Error, Making Two Products Each with Stochastic Demand Schedules

DOI: 10.4236/ajibm.2019.91011, PP. 139-168

Keywords: Optimal Production Control, Corrective Maintenance, Lockout/Tagout, Human Error

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Abstract:

Lockout/tagout (LOTO) is practiced in manufacturing facilities to ensure safety during machinery maintenance procedures. In flexible manufacturing systems, human error (HE) is a major source of accidents and process deviations. Special measures are needed to minimize occupational risk and increase operational efficiency. In this article, we study a production planning problem involving a failure-prone production system meeting two types of demand and we discuss the associated decision-making process. The aim is to develop an optimal, robust and flexible control strategy that facilitates the integration of LOTO into corrective maintenance (CM) and ultimately into production. The influence of HE on flexible manufacturing systems (FMS) is viewed in terms of production and maintenance planning. The frequency of machine repair depends largely on HE. The intrinsic costs of shortage, inventory and CM are optimized over an unbounded planning horizon. Analytical formalism is combined with discrete event simulation, as well as design of experiments (DOE) and a genetic algorithm (GAs) to identify the optimal planning of production and CM with mandatory LOTO. An illustration and sensitivity analysis are proposed to express, in quantitative terms, the usefulness and efficiency of the proposed approach.

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