Skip to main content
SpringerLink
Log in

A two-phase approach for integrating preventive maintenance with production and delivery in an unreliable coal mine

  • Published:
Journal of Heuristics Aims and scope Submit manuscript

Abstract

We consider a coal mine that extracts raw coal by a set of coal mining equipment (CME), separates out multiple products by a set of coal washing equipment, and delivers the products through a fleet of trains over a multi-period horizon. The equipment requires a daily preventive maintenance (PM) and each CME is subject to random failures and repairs. We study a joint PM, production, and delivery problem that determines when to perform the PM and how to manage coal production and delivery in each period, to minimize the expected total cost. We formulate a multi-period stochastic optimization model that delicately integrates the static PM decisions with the adaptive production-delivery decisions, which is extremely difficult to solve due to CME’s decision-dependent operating status. We propose a novel two-phase solution approach to overcome this difficulty. Phase 1 firstly determines the PM decisions using a scenario-based variable neighborhood search algorithm. Using the PM solution and the resultant set of scenarios as input parameters, Phase 2 adaptively determines the production-delivery decisions using a forward-looking algorithm in a rolling horizon manner. We show numerically that our approach consistently produces good-quality and robust solutions while preserving tractability for varying problem instances.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 2
Fig. 3

Similar content being viewed by others

References

  • Adenso-Diaz, B., Lev, B., Artime, R.: Simulation in dynamic environments: optimization of transportation inside a coal mine. IIE Trans. 36(6), 547–555 (2004)

    Article  Google Scholar 

  • AlDurgam, M.M., Duffuaa, S.O.: Optimal joint maintenance and operation policies to maximise overall systems effectiveness. Int. J. Prod. Res. 51(5), 1319–1330 (2013)

    Article  Google Scholar 

  • Alexandros, D.C., Chrissoleon, P.T.: Exact analysis of a two-workstation one-buffer flow line with parallel unreliable machines. Eur. J. Oper. Res. 197(2), 572–580 (2009)

  • Allaoui, H., Lamouri, S., Artiba, A., Aghezzaf, E.: Simultaneously scheduling N jobs and the preventive maintenance on the two-machine flow shop to minimize the makespan. Int. J. Prod. Econ. 112(1), 161–167 (2008)

    Article  Google Scholar 

  • Assid, M., Gharbi, A., Hajji, A.: Joint production, setup and preventive maintenance policies of unreliable two-product manufacturing systems. Int. J. Prod. Res. 53(15), 4668–4683 (2015)

    Article  Google Scholar 

  • Aramon Bajestani, M., Beck, J.C.: A two-stage coupled algorithm for an integrated maintenance planning and flowshop scheduling problem with deteriorating machines. J. Sched. 18(5), 471–486 (2015)

    Article  MathSciNet  MATH  Google Scholar 

  • BP: Statistical Review of World Energy 2018. https://www.bp.com/en/global/corporate/energy-economics/statistical-review-of-world-energy.html (2018)

  • CNPC Economics & Technology Research Institute. China Energy Outlook 2050. https://eneken.ieej.or.jp/data/8192.pdf (2017)

  • Chansombat, S., Pongcharoen, P., Hicks, C.: A mixed-integer linear programming model for integrated production and preventive maintenance scheduling in the capital goods industry. Int. J. Prod. Res. 57(1), 61–82 (2019)

    Article  Google Scholar 

  • Dehayem Nodem, F.I., Kenn, J.P., Gharbi, A.: Simultaneous control of production, repair/replacement and preventive maintenance of deteriorating manufacturing systems. Int. J. Prod. Econ. 134(1), 271–282 (2011)

    Article  Google Scholar 

  • Detti, P., Nicosia, G., Pacifici, A., de Lara, G.Z.M.: Robust single machine scheduling with a flexible maintenance activity. Comput. Oper. Res. 107, 19–31 (2017)

  • de Paula, M.R., Boland, N., Ernst, A.T., Mendes, A., Savelsbergh, M.: Throughput optimisation in a coal export system with multiple terminals and shared resources. Comput. Ind. Eng. 134, 37–51 (2019)

  • Dhouib, K., Gharbi, A., Ben Aziza, M.N.: Joint optimal production control/preventive maintenance policy for imperfect process manufacturing cell. Int. J. Prod. Econ. 137(1), 126–136 (2012)

    Article  Google Scholar 

  • Dong J., Ye, C.M.: Research on two-stage joint optimization problem of green manufacturing and maintenance for semiconductor wafer. Math. Probl. Eng. (2020)

  • Duarte A., Pardo, E.G.: Special issue on recent innovations in variable neighborhood search. J. Heuristics 26, 335–338 (2020)

  • El Khoukhi, F., Boukachour, J., Alaoui, A.E.: The Dual-Ants Colony: a novel hybrid approach for the flexible job shop scheduling problem with preventive maintenance. Comput. Ind. Eng. 106, 236–255 (2017)

    Article  Google Scholar 

  • Feng, Y., Ryan, S.M.: Scenario construction and reduction applied to stochastic power generation expansion planning. Comput. Oper. Res. 40(1), 9–23 (2013)

    Article  MATH  Google Scholar 

  • Finke, G., Gara-Ali, A., Espinouse, M.L., Jost, V., Moncel, J.: Unified matrix approach to solve production-maintenance problems on a single machine. Omega 66, 140–146 (2017)

    Article  Google Scholar 

  • Guo, H., Zhu, K., Ding, C., Li, L.: Intelligent optimization for project scheduling of the first mining face in coal mining. Expert Syst. Appl. 37(2), 1294–1301 (2010)

    Article  Google Scholar 

  • Gharbi, A., Kenn, J.P., Beit, M.: Optimal safety stocks and preventive maintenance periods in unreliable manufacturing systems. Int. J. Prod. Econ. 107(2), 422–434 (2007)

    Article  Google Scholar 

  • Hajej, Z., Turki, S., Rezg, N.: Modelling and analysis for sequentially optimising production, maintenance and delivery activities taking into account product returns. Int. J. Prod. Res. 53(15–16), 4694–4719 (2015)

    Article  Google Scholar 

  • Hajej, Z., Nidhal, R., Anis, C., Bouzoubaa, M.: An optimal integrated production and maintenance strategy for a multi-wind turbines system. Int. J. Prod. Res. 58(21), 6417–6440 (2020)

    Article  Google Scholar 

  • He, Y., Gu, C., Chen, Z., Han, X.: Integrated predictive maintenance strategy for manufacturing systems by combining quality control and mission reliability analysis. Int. J. Prod. Res. 55(19), 5841–586 (2017)

    Article  Google Scholar 

  • Heitsch, H., Römisch, W.: Scenario reduction algorithms in stochastic programming. Comput. Optim. Appl. 24(2–3), 187–206 (2003)

    Article  MathSciNet  MATH  Google Scholar 

  • Içyüz-Ay, I.E., Richard, J.P.P., Eskigun, E., Acharya, D.: A two-model solution approach for the monthly coal train reservations planning problem. Transp. Sci. 50(3), 926–946 (2016)

    Article  Google Scholar 

  • Jiu, S., Zhou, Z., Liu, J.: The equipment maintenance scheduling problem in a coal production system. Int. J. Prod. Res. 51(17), 5309–5336 (2013)

    Article  Google Scholar 

  • Kozan, E., Liu, S.: A demand-responsive decision support system for coal transportation. Decis. Support Syst. 54(1), 665–680 (2012)

    Article  Google Scholar 

  • Lei, D.M., Liu, M.Y.: An artificial bee colony with division for distributed unrelated parallel machine scheduling with preventive maintenance. Comput. Ind. Eng. 141, 106320 (2020)

    Article  Google Scholar 

  • Li, G., Liu, M.Q., Sethi, S.P., Xu, D.H.: Parallel-machine scheduling with machine-dependent maintenance periodic recycles. Int. J. Prod. Econ. 186, 1–7 (2017)

    Article  Google Scholar 

  • Liu, S., Kozan, E.: Optimising a coal rail network under capacity constraints. Flexible Serv. Manuf. J. 23(2), 90–110 (2011)

    Article  MATH  Google Scholar 

  • Liu, J., Yang, S., Wu, A., Hu, S.J.: Multi-state throughput analysis of a two-stage manufacturing system with parallel unreliable machines and a finite buffer. Eur. J. Oper. Res. 219(2), 296–304 (2012)

    Article  MathSciNet  MATH  Google Scholar 

  • Masoud, M., Kozan, E., Kent, G., Liu, S.: A new constraint programming approach for optimising a coal rail system. Optim. Lett. 11(4), 725–738 (2017)

    Article  MathSciNet  MATH  Google Scholar 

  • Miyata, H.H., Nagano, M.S., Gupta, J.N.D.: Integrating preventive maintenance activities to the no-wait flow shop scheduling problem with dependent-sequence setup times and makespan minimization. Comput. Ind. Eng. 135, 79–104 (2019)

    Article  Google Scholar 

  • Mladenović, N., Hansen, P.: Variable neighborhood search. Comput. Oper. Res. 24(11), 1097–1100 (1997)

    Article  MathSciNet  MATH  Google Scholar 

  • Pan, E., Liao, W., Xi, L.: Single-machine-based production scheduling model integrated preventive maintenance planning. Int. J. Adv. Manuf. Technol. 50(1–4), 365–375 (2010)

    Article  Google Scholar 

  • Pendharkar, P.C.: A fuzzy linear programming model for production planning in coal mines. Comput. Oper. Res. 24(12), 1141–1149 (1997)

    Article  MATH  Google Scholar 

  • Pendharkar, P.C., Rodger, J.A.: Nonlinear programming and genetic search application for production scheduling in coal mines. Ann. Oper. Res. 95(1–4), 251–267 (2000)

    Article  MATH  Google Scholar 

  • Peng, H., Van Houtum, G.J.: Joint optimization of condition-based maintenance and production lot-sizing. Eur. J. Oper. Res. 253(1), 94–107 (2016)

    Article  MathSciNet  MATH  Google Scholar 

  • Sarin, S.C., West-Hansen, J.: The long-term mine production scheduling problem. IIE Trans. 37(2), 109–121 (2005)

    Article  Google Scholar 

  • Seif, J., Yu, A.J., Rahmanniyay, F.: Modelling and optimization of a bi-objective flow shop scheduling with diverse maintenance requirements. Int. J. Prod. Res. 56(9), 3204–3225 (2017)

    Article  Google Scholar 

  • Sharma, A., Yadava, G., Deshmukh, S.: A literature review and future perspectives on maintenance optimization. J. Qual. Maint. Eng. 17(1), 5–25 (2011)

    Article  Google Scholar 

  • Shishvan, M.S., Benndorf, J.: Simulation-based optimization approach for material dispatching in continuous mining systems. Eur. J. Oper. Res. 275(3), 1108–1125 (2019)

    Article  Google Scholar 

  • Song, D.P.: Production and preventive maintenance control in a stochastic manufacturing system. Int. J. Prod. Econ. 119(1), 101–11 (2009)

    Article  Google Scholar 

  • Thornblad, K., Stromberg, A.B., Patriksson, M., Almgren, T.: Scheduling optimisation of a real flexible job shop including fixture availability and preventive maintenance. Eur. J. Ind. Eng. 9(1), 126–145 (2015)

    Article  Google Scholar 

  • Wang, T., Baldacci, R., Lim, A., Hu, Q.: A branch-and-price algorithm for scheduling of deteriorating jobs and flexible periodic maintenance on a single machine. Eur. J. Oper. Res. 271(3), 826–838 (2018)

    Article  MathSciNet  MATH  Google Scholar 

  • Wang, S., Liu, M.: Two-machine flow shop scheduling integrated with preventive maintenance planning. Int. J. Syst. Sci. 47(3), 672–690 (2016)

    Article  MathSciNet  MATH  Google Scholar 

  • Wang, S., Yu, J.: An effective heuristic for flexible job-shop scheduling problem with maintenance activities. Comput. Ind. Eng. 59, 436–447 (2010)

    Article  Google Scholar 

  • Wu, X., Zhang, K., Cheng, M.: Computational method for optimal machine scheduling problem with maintenance and production. Int. J. Prod. Res. 55(6), 1791–1814 (2016)

    Article  Google Scholar 

  • Xiang, Y.S., Cassady, C.R., Jin, T.: Joint production and maintenance planning with machine deterioration and random yield. Int. J. Prod. Res. 52(6), 1644–1657 (2014)

    Article  Google Scholar 

  • Yoo, J., Lee, I.S.: Parallel machine scheduling with maintenance activities. Comput. Ind. Eng. 101, 361–371 (2016)

    Article  Google Scholar 

  • Zhao, F., Wang, W., Peng, R.: Delay-time-based preventive maintenance modelling for a production plant: a case study in a steel mill. J. Oper. Res. Soc. 66(12), 2015–2024 (2015)

    Article  Google Scholar 

  • Zhang, R., Sun, X.: Integrated production-delivery lot sizing model with limited production capacity and transportation cost considering overtime work and maintenance time. Math. Probl. Eng. 2018, 1–10 (2018)

    MathSciNet  MATH  Google Scholar 

Download references

Acknowledgements

The author thanks the associate editor and the two anonymous referees for their valuable comments toward improving this study. The author is grateful for the support from the Southwest Jiaotong University under the Qingmiao Program and the Fundamental Research Funds for the Central Universities (No. A1420502052101-48).

Author information

Authors and Affiliations

  1. School of Economics and Management, Southwest Jiaotong University, Chengdu, 610031, China

    Song Jiu

Authors
  1. Song Jiu
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Song Jiu.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Jiu, S. A two-phase approach for integrating preventive maintenance with production and delivery in an unreliable coal mine. J Heuristics 27, 991–1020 (2021). https://doi.org/10.1007/s10732-021-09482-0

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s10732-021-09482-0

Keywords

Search

Navigation