TY - JOUR
T1 - Simulation Optimization of Failure-Prone Manufacturing Systems Considering Reliability-Centered Maintenance and Defective Items Return
AU - Tavan, Fereshteh
AU - Sajadi, Seyed Mojtaba
AU - Sobhani, Farzad Movahedi
AU - Azizi, Amir
N1 - Copyright © The Author(s) 2025. This article is distributed under the terms of the Creative Commons Attribution-NonCommercial 4.0 License (https://creativecommons.org/licenses/by-nc/4.0/) which permits non-commercial use, reproduction and distribution of the work without further permission provided the original work is attributed as specified on the SAGE and Open Access page (https://us.sagepub.com/en-us/nam/open-access-at-sage).
PY - 2025/12
Y1 - 2025/12
N2 - Production planning is a crucial activity in manufacturing systems. However, the failure of production units in these systems is inevitable and can disrupt the production processes. Implementing preventive maintenance and repair strategies can enhance competitiveness in the market, reduce machines failures, and optimize production unit performance. The objective of this article is to develop a reliability-centered maintenance and production control policy that minimizes the total cost of production, perishable product, scrap, rework, and corrective and preventive maintenance in the long term. To achieve this, a simulation of a multi-unit production system with multiple products is conducted, assuming the presence of perishable items, and the performance indicators of the system are calculated. Then, the system is optimized using meta-heuristic coding methods in ARENA software 14. The numerical examples demonstrate that the implementation of the control policy, along with the reliability-centered maintenance, significantly reduces the costs and risks about 5% associated with system uncertainty.
AB - Production planning is a crucial activity in manufacturing systems. However, the failure of production units in these systems is inevitable and can disrupt the production processes. Implementing preventive maintenance and repair strategies can enhance competitiveness in the market, reduce machines failures, and optimize production unit performance. The objective of this article is to develop a reliability-centered maintenance and production control policy that minimizes the total cost of production, perishable product, scrap, rework, and corrective and preventive maintenance in the long term. To achieve this, a simulation of a multi-unit production system with multiple products is conducted, assuming the presence of perishable items, and the performance indicators of the system are calculated. Then, the system is optimized using meta-heuristic coding methods in ARENA software 14. The numerical examples demonstrate that the implementation of the control policy, along with the reliability-centered maintenance, significantly reduces the costs and risks about 5% associated with system uncertainty.
UR - https://journals.sagepub.com/doi/10.1177/00375497251370749
UR - http://www.scopus.com/inward/record.url?scp=105019571755&partnerID=8YFLogxK
U2 - 10.1177/00375497251370749
DO - 10.1177/00375497251370749
M3 - Article
VL - 101
SP - 1201
EP - 1233
JO - Simulation
JF - Simulation
IS - 12
ER -