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ISSN : 1598-7248 (Print)
ISSN : 2234-6473 (Online)
Industrial Engineering & Management Systems Vol.7 No.2 pp.114-125
DOI :

Integrating Machine Reliability and Preventive Maintenance Planning in Manufacturing Cell Design

R.S. Lashkari, 1Kanchan Das, 2S. Sengupta
University of Windsor, Windsor, Ontario N9B 3P4 CANADA
1East Carolina University, Greenville, NC 27858, USA

2Oakland University, Rochester, Michigan 48309-4401 U.S.A.
Selected paper from APIEM 2006

Abstract

This paper presents a model for designing cellular manufacturing systems (CMS) by integrating system cost, machine reliability, and preventive maintenance (PM) planning. In a CMS, a part is processed using alternative process routes, each consisting of a sequence of visits to machines. Thus, a level of ‘system reliability’ is associated with the machines along the process route assigned to a part type. Assuming machine reliabilities to follow the Weibull distribution, the model assigns the machines to cells, and selects, for each part type, a process route which maximizes the overall system reliability and minimizes the total costs of manufacturing operations, machine underutilization, and inter-cell material handling. The model also incorporates a reliability based PM plan and an algorithm to implement the plan. The algorithm determines effective PM intervals for the CMS machines based on a group maintenance policy and thus minimizes the maintenance costs subject to acceptable machine reliability thresholds. The model is a large mixed integer linear program, and is solved using LINGO. The results point out that integrating PM in the CMS design improves the overall system reliability markedly, and reduces the total costs significantly.

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