Integration of maintenance and production strategies under subcontracting constraint: Classification and opportunity

Authors

  • N. Hafidi Faculty of Sciences and technologies, Mechanical Engineering Laboratory, Sidi Mohamed Ben Abdellah University, Route d'Imouzzer, BP. 2202, Fes, Morocco
  • A. El Barkany Faculty of Sciences and technologies, Mechanical Engineering Laboratory, Sidi Mohamed Ben Abdellah University, Route d'Imouzzer, BP. 2202, Fes, Morocco
  • M. Mahmoudi Faculty of Sciences and technologies, Mechanical Engineering Laboratory, Sidi Mohamed Ben Abdellah University, Route d'Imouzzer, BP. 2202, Fes, Morocco

DOI:

https://doi.org/10.15282/jmes.11.3.2017.8.0259

Keywords:

Production; maintenance; coupling; subcontracting; optimisation.

Abstract

The main concern of the manufacturing industry is maintaining the tools of production so that they are in good working order. However, the maintenance and production functions are linked because the integrated management of these two functions is necessary for the efficient operation of the means of production. In fact, when the demand exceeds the maximum production capacity, the company takes on subcontracting to meet the needs of the customers. The objective of this research is to identify the current and future direction of research in this field according to the different classification criteria proposed. In this paper, firstly, the different approaches of maintenance integrated into production systems are presented. Secondly, the models that deal with joint maintenance management and subcontracting production as a solution that aligns with the company's strategic objectives are discussed as well as the resolution and management approaches that integrated problem optimisation. Finally, a comparative study of existing approaches was conducted and their purpose analysed. As perspective, we will propose and implement in our future research a model and powerful tool to establish a better policy of maintenance integrated to the production using subcontracting.

References

Mifdal L, Hajej Z, Dellagi S. Joint Optimization Approach of Maintenance and Production Planning for a Multiple-Product Manufacturing System. Mathematical Problems in Engineering. 2015;2015:1-17.

Hadidi LA, Turki UMA, Rahim A. Integrated models in production planning and scheduling, maintenance and quality: a review. International Journal of Industrial and Systems Engineering. 2012;10:21.

Zied H, Sofiene D, Nidhal R. An optimal maintenance planning according to production rate satisfying random demand. In: Control and Fault-Tolerant Systems (SysTol), 2010 Conference on; 2010. p. 418-23.

Aramon Bajestani M, Banjevic D, Beck JC. Integrated maintenance planning and production scheduling with Markovian deteriorating machine conditions. International Journal of Production Research. 2014;52:7377-400.

Dehayem Nodem FI, Kenné JP, Gharbi A. Simultaneous control of production, repair/replacement and preventive maintenance of deteriorating manufacturing systems. International Journal of Production Economics. 2011;134:271-82.

Ayed S, Hajej Z, Turki S, Rezg N. FPA method for optimal production planning under availability/degradation machine and subcontracting constraint. International Journal of Production Research. 2017;55:2135-48.

Zied H, Sofiene D, Nidhal R. Joint optimisation of maintenance and production policies with subcontracting and product returns. Journal of Intelligent Manufacturing. 2014:1-14.

Mohamed NMZN, Khan MK. Decomposition of Manufacturing Processes: A Review. International Journal of Automotive and Mechanical Engineering. 2012;5:545-60.

Shahin A. The relationship between quality and productivity: a new perspective. International Journal of Productivity and Quality Management. 2008;3:206.

Buzacott JA, Shanthikumar JG. Stochastic models of manufacturing systems. Englewood Cliffs, N.J: Prentice Hall; 1993.

Dallery Y, Gershwin SB. Manufacturing flow line systems: a review of models and analytical results. Queueing Systems. 1992;12:3-94.

Xie X. Performance analysis of a transfer line with unreliable machines and finite buffers. IIE Transactions. 1993;25:99-108.

Van der Duyn Schouten FA, Vanneste SG. Maintenance optimization of a production system with buffer capacity. European Journal of Operational Research. 1995;82:323-38.

Meller RD, Kim DS. The impact of preventive maintenance on system cost and buffer size. European Journal of Operational Research. 1996;95:577-91.

Mansor MA, Ohsato A, Sulaiman S. Knowledge Management for Maintenance Activities in the Manufacturing Sector. International Journal of Automotive and Mechanical Engineering. 2012;5:612-21.

Andrew-Munot M, Ibrahim RN. Remanufacturing Process and Its Challenges. Journal of Mechanical Engineering and Sciences. 2013;4:488-95.

Kenne JP, Boukas EK, Gharbi A. Control of production and corrective maintenance rates in a multiple-machine, multiple-product manufacturing system. Mathematical and Computer Modelling. 2003;38:351-65.

Gharbi A, Kenne JP. Production and preventive maintenance rates control for a manufacturing system: An experimental design approach. International Journal of Production Economics. 2000;65:275-87.

Bergeron D, Jamali MA, Ait-Kadi D. Coupling Simulation and Optimization for an Integrated Production and Maintenance Planning in Manufacturing Systems. IFAC Proceedings Volumes. 2009;42:1091-5.

Kenné JP, Boukas EK. Hierarchical control of production and maintenance rates in manufacturing systems. Journal of Quality in Maintenance Engineering. 2003;9:66-82.

Kenné JP, Gharbi A. Stohastic optimal production control problem with corrective maintenance. Computers & Industrial Engineering. 2004;46:865-75.

Gharbi A, Kenné J-P. Maintenance scheduling and production control of multiple-machine manufacturing systems. Computers & Industrial Engineering. 2005;48:693-707.

Charlot E, Kenné JP, Nadeau S. Optimal production, maintenance and lockout/tagout control policies in manufacturing systems. International Journal of Production Economics. 2007;107:435-50.

Kenne JP, Nkeungoue LJ. Simultaneous control of production, preventive and corrective maintenance rates of a failure-prone manufacturing system. Applied Numerical Mathematics. 2008;58:180-94.

Ben-Salem A, Gharbi A, Hajji A. Environmental issue in an alternative production–maintenance control for unreliable manufacturing system subject to degradation. The International Journal of Advanced Manufacturing Technology. 2015;77:383-98.

OUALI M-S, REZG N, XIAOLAN X. Maintenance préventive et optimisation des flux d'un système de production. Journal européen des systèmes automatisés. 2002;36:97-116.

Yalaoui A, Chaabi K, Yalaoui F. Integrated production planning and preventive maintenance in deteriorating production systems. Information Sciences. 2014;278:841-61.

Roux O, Duvivier D, Quesnel G, Ramat E. Optimization of preventive maintenance through a combined maintenance-production simulation model. International Journal of Production Economics. 2013;143:3-12.

Zied H, Sofiene D, Nidhal R. An optimal production/maintenance planning under stochastic random demand, service level and failure rate. In: Automation Science and Engineering, 2009 CASE 2009 IEEE International Conference on; 2009. p. 292-7.

Zied H, Sofiene D, Nidhal R. Optimal integrated maintenance/production policy for randomly failing systems with variable failure rate. International Journal of Production Research. 2011;49:5695-712.

Benbouzid Sitayeb F. Contribution à l'étude de la performance et de la robustesse des ordonnancements conjoints production/maintenance: cas du flowshop: Besançon; 2005.

Fitouhi M-C, Nourelfath M. Integrating noncyclical preventive maintenance scheduling and production planning for multi-state systems. Reliability Engineering & System Safety. 2014;121:175-86.

Bouslah B, Gharbi A, Pellerin R. Joint optimal lot sizing and production control policy in an unreliable and imperfect manufacturing system. International Journal of Production Economics. 2013;144:143-56.

Cheng GQ, Zhou BH, Li L. Joint optimisation of production rate and preventive maintenance in machining systems. International Journal of Production Research. 2016;54:6378-94.

Alaoui-Selsouli M, Mohafid A, Najid NM. Lagrangian relaxation based heuristic for an integrated production and maintenance planning problem. International Journal of Production Research. 2012;50:3630-42.

Aghezzaf EH, Jamali MA, Ait-Kadi D. An integrated production and preventive maintenance planning model. European Journal of Operational Research. 2007;181:679-85.

Xiang Y, Cassady CR, Jin T, Zhang CW. Joint production and maintenance planning with machine deterioration and random yield. International Journal of Production Research. 2014;52:1644-57.

Bennour M, Bloch C, Zerhouni N. Modélisation intégrée des activités de maintenance et de production. In: 3e Conférence Francophone de Modélisation et de SIMulation MOSIM’01; 2001. p. 805-10.

Najid NM, Alaoui-Selsouli M, Mohafid A. An integrated production and maintenance planning model with time windows and shortage cost. International Journal of Production Research. 2011;49:2265-83.

Salameh MK, Ghattas RE. Optimal just-in-time buffer inventory for regular preventive maintenance. International Journal of Production Economics. 2001;74:157-61.

El-Kassar A, Salameh M. Safety Butter for Preventive maintenance and Breakdown. Porto, Portugal; 2003.

Rezg N, Xie X, Mati Y. Joint optimization of preventive maintenance and inventory control in a production line using simulation. International Journal of Production Research. 2004;42:2029-46.

Chelbi A, Ait-Kadi D. Analysis of a production/inventory system with randomly failing production unit submitted to regular preventive maintenance. European Journal of Operational Research. 2004;156:712-8.

Kenné J-P, Gharbi A, Beit M. Age-dependent production planning and maintenance strategies in unreliable manufacturing systems with lost sale. European Journal of Operational Research. 2007;178:408-20.

Srinivasan MM, Lee H-S. Production-Inventory Systems with Preventive Maintenance. IIE Transactions. 1996;28:879-90.

Weinstein L, Chung C-H. Integrating maintenance and production decisions in a hierarchical production planning environment. Computers & Operations Research. 1999;26:1059-74.

Yao X, Xie X, Fu MC, Marcus SI. Optimal joint preventive maintenance and production policies. Naval Research Logistics. 2005;52:668-81.

Iravani SMR, Duenyas I. Integrated maintenance and production control of a deteriorating production system. IIE Transactions. 2002;34:423-35.

Gharbi A, Kenné J-P, Beit M. Optimal safety stocks and preventive maintenance periods in unreliable manufacturing systems. International Journal of Production Economics. 2007;107:422-34.

Liao G-L. Optimal production correction and maintenance policy for imperfect process. European Journal of Operational Research. 2007;182:1140-9.

Berthaut F, Gharbi A, Kenné J-P, Boulet J-F. Improved joint preventive maintenance and hedging point policy. International Journal of Production Economics. 2010;127:60-72.

Brandolese M, Franci M, Pozzetti* A. Production and maintenance integrated planning. International Journal of Production Research. 1996;34:2059-75.

Cassady CR, Kutanoglu E. Minimizing Job Tardiness Using Integrated Preventive Maintenance Planning and Production Scheduling. IIE Transactions. 2003;35:503-13.

Pandey D, Kulkarni MS, Vrat P. A methodology for joint optimization for maintenance planning, process quality and production scheduling. Computers & Industrial Engineering. 2011;61:1098-106.

Hadidi LA, Turki UMA, Rahim MA. An integrated cost model for production scheduling and perfect maintenance. International Journal of Mathematics in Operational Research. 2011;3:395.

Hnaien F, Yalaoui F, Mhadhbi A, Nourelfath M. A mixed-integer programming model for integrated production and maintenance. IFAC-PapersOnLine. 2016;49:556-61.

Sortrakul N, Nachtmann HL, Cassady CR. Genetic algorithms for integrated preventive maintenance planning and production scheduling for a single machine. Computers in Industry. 2005;56:161-8.

Ramirez Restrepo LM, Hennequin S, Aguezzoul A. Optimization of integrated preventive maintenance based on infinitesimal perturbation analysis. Computers & Industrial Engineering. 2016;98:470-82.

Wang S, Liu M. A branch and bound algorithm for single-machine production scheduling integrated with preventive maintenance planning. International Journal of Production Research. 2013;51:847-68.

Berthaut F, Gharbi A, Dhouib K. Joint modified block replacement and production/inventory control policy for a failure-prone manufacturing cell. Omega. 2011;39:642-54.

Cassady CR, Kutanoglu E. Integrating Preventive Maintenance Planning and Production Scheduling for a Single Machine. IEEE Transactions on Reliability. 2005;54:304-9.

Cui W-W, Lu Z, Pan E. Integrated production scheduling and maintenance policy for robustness in a single machine. Computers & Operations Research. 2014;47:81-91.

Sortrakul N, Cassady CR. Genetic algorithms for total weighted expected tardiness integrated preventive maintenance planning and production scheduling for a single machine. Journal of Quality in Maintenance Engineering. 2007;13:49-61.

Mehdi R, Nidhal R, Anis C. Integrated maintenance and control policy based on quality control. Computers & Industrial Engineering. 2010;58:443-51.

Yulan J, Zuhua J, Wenrui H. Multi-objective integrated optimization research on preventive maintenance planning and production scheduling for a single machine. The International Journal of Advanced Manufacturing Technology. 2008;39:954-64.

Lu Z, Cui W, Han X. Integrated production and preventive maintenance scheduling for a single machine with failure uncertainty. Computers & Industrial Engineering. 2015;80:236-44.

Berrichi A, Amodeo L, Yalaoui F, Châtelet E, Mezghiche M. Bi-objective optimization algorithms for joint production and maintenance scheduling: application to the parallel machine problem. Journal of Intelligent Manufacturing. 2009;20:389-400.

Nourelfath M, Châtelet E. Integrating production, inventory and maintenance planning for a parallel system with dependent components. Reliability Engineering & System Safety. 2012;101:59-66.

Nourelfath M, Nahas N, Ben-Daya M. Integrated preventive maintenance and production decisions for imperfect processes. Reliability Engineering & System Safety. 2016;148:21-31.

Gouiaa-Mtibaa A, Dellagi S, Achour Z, Erray W. Integrated Maintenance-Quality strategies with reworking activities. IFAC-PapersOnLine. 2016;49:61-6.

Ben-Daya M, Duffuaa S. Maintenance and quality: the missing link. Journal of Quality in Maintenance Engineering. 1995;1:20-6.

Ben-Daya M, Makhdoum M. Integrated Production and Quality Model under Various Preventive Maintenance Policies. The Journal of the Operational Research Society. 1998;49:840.

Bouslah B, Gharbi A, Pellerin R. Integrated production, sampling quality control and maintenance of deteriorating production systems with AOQL constraint. Omega. 2016;61:110-26.

Colledani M, Tolio T. Integrated quality, production logistics and maintenance analysis of multi-stage asynchronous manufacturing systems with degrading machines. CIRP Annals. 2012;61:455-8.

Pandey D, Kulkarni MS, Vrat P. Joint consideration of production scheduling, maintenance and quality policies: a review and conceptual framework. International Journal of Advanced Operations Management. 2010;2:1-24.

Abdulnour G, Dudek RA, Smith ML. Effect of maintenance policies on the just-in-time production system. International Journal of Production Research. 1995;33:565-83.

Groenevelt H, Pintelon L, Seidmann A. Production Batching with Machine Breakdowns and Safety Stocks. Operations Research. 1992;40:959-71.

Makis V, Fung J. Optimal preventive replacement, lot sizing and inspection policy for a deteriorating production system. Journal of Quality in Maintenance Engineering. 1995;1:41-55.

Chung K-J. Approximations to production lot sizing with machine breakdowns. Computers & Operations Research. 2003;30:1499-507.

Wang C-H, Sheu SH. Determining the optimal production–maintenance policy with inspection errors: using a Markov chain. Computers & Operations Research. 2003;30:1-17.

Budai G, Dekker R, Nicolai RP. A review of planning models for maintenance and production. Economic Institute report. 2006:2006-44.

Chelbi A, Rezg N. Analysis of a production/inventory system with randomly failing production unit subjected to a minimum required availability level. International Journal of Production Economics. 2006;99:131-43.

Chelbi A, Aït-Kadi D. Joint Optimal Buffer Inventory and Preventive Maintenance Strategy for a Randomly Failing Production Unit. Journal of Decision Systems. 2003;12:21-30.

Ben-Daya M. Integrated production maintenance and quality model for imperfect processes. IIE Transactions. 1999;31:491-501.

Ben-Daya M. The economic production lot-sizing problem with imperfect production processes and imperfect maintenance. International Journal of Production Economics. 2002;76:257-64.

Colledani M, Ebrahimi D, Tolio T. Integrated quality and production logistics modelling for the design of selective and adaptive assembly systems. CIRP Annals. 2014;63:453-6.

Cagliano R, Spina G. A comparison of practice‐performance models between small manufacturers and subcontractors. International Journal of Operations & Production Management. 2002;22:1367-88.

Chaillou B. Définition et typologie de la sous-traitance. Revue économique. 1977:262-85.

Amesse F, Dragoste L, Nollet J, Ponce S. Issues on partnering: evidences from subcontracting in aeronautics. Technovation. 2001;21:559-69.

Seillan H, Morvan J. Risques de la sous-traitance: Éd." Préventique; 2005.

Bandyopadhyay S, Pathak P. Knowledge sharing and cooperation in outsourcing projects — A game theoretic analysis. Decision Support Systems. 2007;43:349-58.

Genthon V. La sous-traitance industrielle: un phénomène en croissance. Le 4 pages des Statistiques Industrielles. 2000;131.

Hery M. Besoins de recherches en santé sécurité du travail pour les salariés de la sous-traitance interne. Pistes. 2002;4:11.

Gorgeu A, Mathieu R. Dix ans de relations de sous-traitance dans l'industrie française. Travail. 1993;28:23-44.

Doniol-Shaw G. Sous-traitance et maintenance des centrales nucléaires. Travail. 1993;28:53-64.

Grusenmeyer C. Sous-traitance et accidents. Exploitation de la base de données EPICEA. INRS; 2007.

Andersen PH. Organizing international technological collaboration in subcontractor relationships: an investigation of the knowledge-stickiness problem. Research Policy. 1999;28:625-42.

Bertrand JWM, Sridharan V. A study of simple rules for subcontracting in make-to-order manufacturing. European Journal of Operational Research. 2001;128:509-31.

Berry A. SME competitiveness: the power of networking and subcontracting. Inter-American Development Bank; 1997.

Andersen PH, Christensen PR. Inter-partner learning in global supply chains: lessons from NOVO Nordisk. European Journal of Purchasing & Supply Management. 2000;6:105-16.

Gomes-Casseres B. Group versus group: How alliance networks compete. Harvard business review. 1994;72:62-6.

ICSI. À quoi faut-il penser, vis-à-vis de la sécurité, avant la décision éventuelle de sous-traiter? Toulouse, France: Cahiers de la Sécurité Industrielle, Institute for an Industrial Safety Culture; 2008.

Bravard J-L, Morgan R. Smarter outsourcing: An executive guide to understanding, planning and exploiting successful outsourcing relationships: Pearson Education; 2006.

Barthélemy J. Stratégies d'externalisation: Préparer, décider et mettre en oeuvre l'externalisation d'activités stratégiques: Dunod; 2007.

Thébaud-Mony A. Travailler peut nuire gravement à la santé. Paris, La Découverte. 2007.

Tazi D. Externalisation de la maintenance et sécurité: une analyse bibliographique. Rapport technique, Institut pour une Culture de Sécurité Industrielle. 2010.

Dror M, Smith KR, Yano CA. Deux Chemicals Inc. Goes Just-in-Time. Interfaces. 2009;39:503-15.

Assid M, Gharbi A, Dhouib K. Joint production and subcontracting planning of unreliable multi-facility multi-product production systems. Omega. 2015;50:54-69.

Chouikhi H, Dellagi S, Rezg N. Development and optimisation of a maintenance policy under environmental constraints. International Journal of Production Research. 2012;50:3612-20.

Haoues M, Dahane M, Mouss NK, Rezg N. Integrated Optimisation of In-House Production and Outsourcing Strategy: Genetic Algorithm Based Approach. IFAC Proceedings Volumes. 2013;46:420-5.

Suppen N, Onosato M, Iwata K. A life-cycle maintenance methodology with environmental, health and safety considerations. 1999. p. 875-9.

Dellagi S, Rezg N. Production/maintenance policies optimization in a subcontractor environment. Alexandria Egypt; 2007. p. 178-89.

Dellagi S, Rezg N, Xie X. Preventive maintenance of manufacturing systems under environmental constraints. International Journal of Production Research. 2007;45:1233-54.

Dellagi S, Rezg N, Gharbi A. Optimal maintenance/production policy for a manufacturing system subjected to random failure and calling upon several subcontractors. international journal of management science and engineering management. 2010;5:261-7.

Ayed S, Dellagi S, Rezg N. Développement et optimisation d'une stratégie de maintenance dépendante du plan de production et tenant compte de droit rétractation. 8ème Conférence Internationale de Modélisation et de Simulation-MOSIM 20102010.

Dahane M, Clementz C, Rezg N. Analysis of joint maintenance and production policies under a subcontracting constraint. International Journal of Production Research. 2008;46:5393-416.

Ayed S, Dellagi S, Rezg N. Optimal integrated maintenance production strategy with variable production rate for random demand and subcontracting constraint. IFAC Proceedings Volumes. 2011;44:5207-12.

Ayed S, Sofiene D, Nidhal R. Joint optimisation of maintenance and production policies considering random demand and variable production rate. International Journal of Production Research. 2012;50:6870-85.

Ayed S, Dellagi S, Rezg N. Optimisation d'une politique de maintenance intégrée sous une contrainte de sous-traitance avec contribution de stock. In: 8ème Conférence Internationale de Modélisation et de Simulation-MOSIM 2010; 2010.

Souheil A, Sadok T, Zied H. Perturbation Analysis for Optimal Production Planning Of a Manufacturing System with Subcontracting and Machine Degradation. IFAC-PapersOnLine. 2015;48:2145-52.

Cormier G, Rezg N. Analytical contributions to the joint optimization of maintenance, production and subcontracting. In: International Conference on Industrial Engineering and Systems Management IESM; 2009. p. 13-5.

Rivera-Gómez H, Gharbi A, Kenné J-P, Montaño-Arango O, Hernandez-Gress ES. Production control problem integrating overhaul and subcontracting strategies for a quality deteriorating manufacturing system. International Journal of Production Economics. 2016;171:134-50.

Zied H, Sofiene D, Nidhal R. Production/maintenance policies optimization with operational age concept in a subcontracting constraint. IFAC Proceedings Volumes. 2011;44:5213-8.

Gharbi A, Hajji A, Dhouib K. Production rate control of an unreliable manufacturing cell with adjustable capacity. International Journal of Production Research. 2011;49:6539-57.

Hajej Z, Rezg N, Gharbi A. Improved preventive maintenance in the framework of forecasting problem under subcontractor constraint. International Journal of Production Research. 2017;55:4557-600.

Hajej Z, Rezg N, Gharbi A. Forecasting and maintenance problem under subcontracting constraint with transportation delay. International Journal of Production Research. 2014;52:6695-716.

Safaei N, Tavakkoli-Moghaddam R. Integrated multi-period cell formation and subcontracting production planning in dynamic cellular manufacturing systems. International Journal of Production Economics. 2009;120:301-14.

Hilgers A, Boersma BJ. Optimization of turbulent jet mixing. Fluid Dynamics Research. 2001;29:345-68.

Hao J-K, Galinier P, Habib M. Métaheuristiques pour l’optimisation combinatoire et l’affectation sous contraintes. Revue d’intelligence artificielle. 1999;13:283-324.

Belavendram N. Application of Genetic Algorithms for Robust Parameter Optimization. International Journal of Automotive and Mechanical Engineering. 2010;2:211-20.

Kamal M, Rahman MM. Fatigue life estimation based on continuum mechanics theory with application of genetic algorithm. International Journal of Automotive and Mechanical Engineering. 2015;11:2686-98.

Reeves CR. Modern heuristic techniques for combinatorial problems: John Wiley & Sons, Inc.; 1993.

Aarts EH, Lenstra JK. Local search in combinatorial optimization: Princeton University Press; 1997.

Lebbar G, El Barkany A, Jabri A. Scheduling Problems of Flexible Manufacturing Systems: Review, Classification and Opportunities. International Journal of Engineering Research in Africa. 2016;26:142-60.

Dahane M, Dellagi S, Clementz C, Rezg N. Development of joint maintenance and production strategies in a subcontracting environment. International Journal of Production Research. 2011;49:6937-61.

Liu X, Tu YL, Zhang J, Watson LG. A genetic algorithm heuristic approach to general outsourcing capacitated production planning problems. International Journal of Production Research. 2008;46:5059-74.

Downloads

Published

2017-09-30

How to Cite

[1]
N. Hafidi, A. El Barkany, and M. Mahmoudi, “Integration of maintenance and production strategies under subcontracting constraint: Classification and opportunity”, J. Mech. Eng. Sci., vol. 11, no. 3, pp. 2856–2882, Sep. 2017.