Effect of different maintenance policies on the just-in-time production system
MetadataShow full item record
Fascinated by the success of the Japanese firms using Just-In-Time Production Systems, the American practitioners and researchers are seeking to find ways to implement the J.I.T. concept in and to adapt it to the American production environment. Works on this subject include detailed descriptions of Pull System and J.I.T. implementation, and some qualitative analysis of the feasibility of J.I.T. in different manufacturing environments. To date, little work has been done on quantitative analysis of the performance of Pull Systems, and very few works are relevant to the operational control problem with stochastic machine failure. In this study, mathematical models are developed in order to describe the effect that maintenance policy, production machine unreliability, processing time variability, ratio of preventive maintenance time to processing time, ratio of minimal repair time to preventive maintenance time, and production line size have on performance measures of the production system, which are: total production line output, customer service level, and production line variability. Monte Carlo simulation using GPSS/H as a simulation language was used to simulate the production system and to collect the desired data. Experimental design and regression analysis were utilized to analyze the simulated responses. The analysis of the data shows that under different situations, different maintenance policies do not have the same effect on the production line performance. Therefore, the results of this study should help the user in choosing a maintenance policy as a function of the production process parameters, and once the policy is selected the user can select the most important factors to control under this policy in order to minimize machine idle time, maximize production process reliability, improve productivity, and therefore increase the production line performance.