ANALYSIS OF PRODUCTION STRATEGIES AND REPLACEMENT OF PRODUCTION SYSTEMS UNDER A PROCESS OF DETERIORATION

Abstract

The present article studies the problem of determining the production and replacement strategies for a production system subject to a deterioration process. The manufacturing system is composed of a production unit, which produces a single part type. Due to the deterioration process, the failure rate and the rate of defectives, increases progressively. This paper proposes three strategies that simultaneously control the production rate and the replacement rate that mitigates the effects of the system deterioration. The three control strategies CPR1, CPR2 and CPR3 are analyzed and compared in terms of the total incurred cost. The objective of the models is to minimize the total incurred cost in an infinite horizon. Moreover, a methodology based in statistical analysis of the simulation models and their optimization is proposed, with the objective to determine the optimal control parameters. In order to validate the obtained results, an extensive sensitivity analysis is conducted for both policies, which shows the effect of several costs in their respective control parameters. The obtained results indicate that the CPR3 policy, which needs a security inventory to replace the system, reports a reduction in the total cost compared to the CPR1 and CPR2 policies. Keywords: production systems, deterioration process, production, replacement, simulation.