Joint optimization of quality-based multi-level maintenance and buffer stock within multi-specification and small-batch production

Abstract

This study proposes a comprehensive framework for the joint optimization of maintenance actions and safety stock policies for multi-specification small-batch (MSSB) production. The production system considered consists of multiple machines arranged in a series-parallel configuration. Given the multi-stage nature of the MSSB, a piecewise Gamma process is developed to model the degradation of machines owing to varying product specifications. A quality-based maintenance model is proposed to guide the scheduling of maintenance actions based on the observed product defect rate. The maintenance policy is optimized at two levels: at the machine level, the optimal quality of the produced products is determined, and at the system level, a threshold quality value is established to facilitate the opportunistic maintenance of machines. The relationship between the buffer stock and machine capacity is explicitly modeled to ensure production efficiency. A simulation-based multi-objective algorithm is employed to identify the optimal decision variable levels for the proposed maintenance policy. The numerical results demonstrate that the proposed method effectively balances the conflicting objectives of minimizing the expected operational costs and maximizing production efficiency.

Graphical abstract

Keywords

serial-parallel multi-stage production system / multi-specification and small-batch / multi-level maintenance / quality control / safety stock

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