Production and Maintenance Scheduling for Total Cost and Machine Longevity Optimization

Abstract

Production and maintenance scheduling for total cost-effective and machine longevity manufacturing is a key aspect in dealing with the ever-increasing energy prices, competitiveness, added maintenance costs, and environmental pressures that the manufacturing sector faces nowadays. This paper addresses these issues by proposing a novel intelligent production scheduling system for joint optimization of production and maintenance for overall cost minimization and machine longevity improvement. To achieve this, it is proposed a Genetic Algorithm (GA) for production and maintenance scheduling of flexible job shop manufacturing environments. The proposed GA takes into account volatile market energy prices, Renewable Energy Resources (RERs), surplus energy selling, maintenance activities, and constraints imposed on the production plan. A case study from the literature is used as a baseline scenario to validate the proposed scheduler. It uses real-production data and considers three unique machines with 275 tasks to be scheduled among them. Using the baseline scenario, it was possible to demonstrate the robustness of the proposed scheduler in reducing total costs, by taking advantage of the volatility of energy prices, as well as utilizing RERs to cover energy expenses or for selling excess energy. Furthermore, it highlights the ability to reduce the overload of single machines. Accordingly, it was possible to achieve cost reductions of up to 11.0% and improvements of 24.4% in machine longevity when compared to the baseline scenario.