An optimal production and inspection strategy with preventive maintenance error and rework

This study considers the integrated problem of production, preventive maintenance (PM), inspection, and inventory for an imperfect production process where rework and PM error exist. PM is performed when the process is in a controlled state. The correct implementation of PM results in a lower system failure rate, whereas a PM error results in the system shifting to the out-of-control state with a certain probability. The age of the system after PM is correlated with the level of PM performed. When the process in an out-of-control state produces a certain percentage of non-conforming items, we assume that a certain proportion of the non-conforming items can be reworked into conforming items. In a deteriorating production system, we determine the optimal inspection interval, inspection frequency, and production quantity that will yield the maximal unit expected profit. Numerical analyses are used to investigate the effectiveness of imperfect PM and to explore the effect of rework and PM error on profit. (C) 2012 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.