TITLE:
A Mathematical Model: A Flexible Manufacturing System, Prone to Error, Making Two Products Each with Stochastic Demand Schedules
AUTHORS:
Issa Diop, Sylvie Nadeau, Behnam Emami-Mehrgani
KEYWORDS:
Optimal Production Control, Corrective Maintenance, Lockout/Tagout, Human Error
JOURNAL NAME:
American Journal of Industrial and Business Management,
Vol.9 No.1,
January
16,
2019
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.