Integrated Disassembly and Assembly Model For Heavy Duty Equipment Maintenance
Integrated Disassembly and Assembly Model For Heavy Duty Equipment Maintenance
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* Corresponding
Écoleauthor. Tel.:Supérieure
Nationale +852-9373-2670.
d’Arts et Métiers,
E-mail Arts [email protected]
address: Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
*Abstract
Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: [email protected]
Abstract
This paper investigates a multi-period integrated decision-making model for the heavy duty equipment maintenance involving disassembly,
inspection and assembly with uncertain numbers of replaced parts within a time horizon. There are large numbers of subways cars exported from
This paper investigates a multi-period integrated decision-making model for the heavy duty equipment maintenance involving disassembly,
Abstract
other countries and the maintenance is difficult to be conducted in Hong Kong (HK) due to the limited spaces, machinery and technical supporting
inspection and assembly with uncertain numbers of replaced parts within a time horizon. There are large numbers of subways cars exported from
team. Thus, the efficient maintenance planning is required to ensure the quality of transportation services. To resolve the problem, a deterministic
other
In countries
today’s and the
business maintenance
environment, istrend
difficult to be more
conducted in Hong Kong
and(HK) due to the is
limited spaces, machinery and technicalthe
supporting
mixed integer optimization modelthe is developedtowards
to achieveproduct variety
integrated customization
optimization of disassemblyunbroken. Due
and assembly. to The
this model
development, need
minimizes the of
total
team. Thus, the efficient maintenance planning is required to ensure the quality of transportation services. To resolve the problem, a deterministic
agile and reconfigurable production systems emerged to cope with various products and product families. To design and
operation cost consisting of purchasing cost and repair cost, subject to capacity constraints. A real-life case study from Mass Transit Railway optimize production
mixed integer optimization model is developed to achieve integrated optimization of disassembly and assembly. The model minimizes the total
systems
(MTR) Hongas well as tois choose
Kong presented thetooptimal product
verify the matches,
proposed model.product analysis methods are needed. Indeed, most of the known methods aim to
operation cost consisting of purchasing cost and repair cost, subject to capacity constraints. A real-life case study from Mass Transit Railway
analyze a product or one product family on the physical level. Different product families, however, may differ largely in terms of the number and
(MTR) Hong Kong is presented to verify the proposed model.
nature
© 2019ofThecomponents. This fact by
Authors. Published impedes
Elsevier anB.V.
efficient comparison and choice of appropriate product family combinations for the production
system.
© 2020
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is an new methodology
Authors.
open articleisunder
accessPublished proposed
by Elsevier
the CC to BY-NC-ND
analyze
B.V. existing products
license in view of their functional and physical architecture. The aim is to cluster
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these The
is an
products Authors.
open
inaccess
new Published
assembly by Elsevier
article under B.V.families license
the scientific
oriented CC BY-NC-ND
product for the (http://creativecommons.org/licenses/by-nc-nd/4.0/)
optimization
Peer-review under responsibility of the committee of the 53rd CIRPofConference
existing assembly lines and the
on Manufacturing creation of future reconfigurable
Systems
This is ansystems.
Peer-review
assembly open access
under Based article
responsibility under
on Datum the
the CC
of Flow BY-NC-ND
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the physical (http://creativecommons.org/licenses/by-nc-nd/4.0/)
ofstructure
the 53rdofCIRP Conference
the products on Manufacturing
is analyzed. FunctionalSystems
subassemblies are identified, and
aPeer-review
functional
Keywords:
under responsibility of the scientific committee of the 53rd CIRP Conference on Manufacturing Systems
analysis
Heavy is performed.
duty equipment Moreover,
maintenance; a hybrid
Integrated functional
planning; and physical
Disassembly architecture graph (HyFPAG) is the output which depicts the
and assembly.
similarity between product families by providing design support to both, production system planners and product designers. An illustrative
Keywords: Heavy duty equipment maintenance; Integrated planning; Disassembly and assembly.
example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of
thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach.
©1.2017
Introduction
The Authors. Published by Elsevier B.V. many procedures. However, for heavy duty equipment,
Peer-review under responsibility of the scientific committee of the 28th CIRP
1. Introduction complete
Design maintenance
Conference 2018.is cost-effective and reduces labour cost,
many procedures. However, for heavy duty equipment,
Maintenance services are critical support activities that because replacement
complete maintenanceofisworn parts is more
cost-effective cost effective
and reduces than
labour cost,
Keywords:
extend Assembly;
life Design
lengthservices method; Family
and improve identification
performance of the equipment purchasing new equipment and less time consuming than
Maintenance are critical support activities that because replacement of worn parts is more cost effective than
[1]. Even though maintenance is not a value
extend life length and improve performance of the equipment adding activity, it replacing one part each time [4]. Due
purchasing new equipment and less time consuming thanto the large involvement
does improve
[1]. Even though themaintenance
circularity ofis material
not a value andadding
part use, which
activity, it of components,
replacing one parttheeach
complete
time [4]. maintenance
Due to the is usually
large divided
involvement
reduces
1.does capital
Introduction investment. In some industrial
improve the circularity of material and part use, whichsectors with high into
of the
of several
components, procedures
the complete
product range with a series
maintenance
and characteristics of tasks which
is usually divided
manufactured have
and/or
capital
reducesinvestment, the equipment
capital investment. In some is industrial
highly valuable
sectorsand withheavy,
high designated
into several
assembled time and
procedures
in this standard
system. In with quality
thisacontext, control
series of [5].
the tasks Take Mass
which have
main challenge in
and called
capital heavy
Due investment,
to the fast duty equipment,
the equipment
development such
is highly as subway
in valuable
the domaincars in the
and heavy, of Transit
designated
modelling Railway (MTR)
timeanalysis
and in now
and standard
is Hong Kong
quality
not fortoexample,
control
only there
[5]. with
cope Take Massare
single
metropolitan
and called heavy
communication transportation
and industry,
dutyanequipment,
ongoing suchmining
trend machinery
asofsubway cars in
digitization inand
the
the total
Transit152Railway
products, railway
a limited stations
(MTR)
product inwhere
rangehundreds
Hong Kong forofexample,
or existing heavy-duty
product there trains
families, are
mining industry,
metropolitan
digitalization, and airplanes
transportation
manufacturing in the airline
industry,
enterprises are industry
mining machinery
facing [2].inSuch
important the are running
totalalso
but 152torailwaythrough
be ablestations the
to analyze wherepublic
and hundredstransport
to compare network.
of products
heavy-duty The
trains
to define
equipment
challenges requires
mining industry,
in today’s not only
and airplanes regularly
marketinenvironments: maintenance
the airline industry but Such
[2].
a continuing also maintenance
are product
new for MTR It
runningfamilies.
through includes
the be
can the
public infrastructures
observed transport like railways,
network.
that classical The
existing
complete
equipment
tendency maintenance
requires
towards notat only
reduction regulated intervals.
of regularly
product maintenancetimes
development but also
and electronic
maintenance
product and electrical
for are
families MTR facilities
includesin
regrouped alone
thefunction the railways,
infrastructures
of clients oras
like well as
railways,
features.
Complete
complete product
shortened maintenance
maintenance aims
at regulated
lifecycles. to keep
intervals.
In addition, theretheis equipment
an increasing in subway
electroniccars.
However, Theoriented
and electrical
assembly maintenance
facilities
product offamilies
alone subway cars asplays
the railways,
are hardly well
to asa
find.
serviceable
Complete
demand condition by preventing
maintenancebeing
of customization, all kinds
aims attothekeep
samethe of critical
equipment
time damage
in a global in significant
subway
On thecars. role
product in supporting
Thefamily
maintenance the whole
of subway
level, products MTR transportation
cars plays
differ mainly in twoa
[3]. Compared
serviceable
competition withto competitors
condition regular maintenance,
by preventing complete
all kinds
all over the maintenance
of critical
world. Thisdamage
trend, system sincerole
significant
main there
in are
characteristics: (i)large
supporting numbers
the number ofofcomponents
the whole subways cars
andexported
MTR transportation
(ii) the
is completed
[3].
which Compared in to
is inducing order of disassembly,
regular
the maintenance,
development inspection
complete
from and
macro repair,
maintenance
to microand from
system
type ofother
sincecountries
there are
components and
large
(e.g. the maintenance
numbers
mechanical, of is electronical).
subways
electrical, difficult to be
cars exported
assembly,
is completed
markets, and takes
in order
results longer maintenance
of disassembly,
in diminished time
inspection
lot sizes due to involving
due toandaugmenting
repair, and conducted
from in Hong Kong
other methodologies
countries and the (HK) due to the
maintenance limited resources,
is single
difficult to be
Classical considering mainly products
assembly,
product and takes
varieties longer maintenance
(high-volume to low-volume time due to involving
production) [1]. conducted
or solitary,in already
Hong Kong (HK) product
existing due to thefamilies
limited resources,
analyze the
To cope with
2212-8271 this
© 2019 Theaugmenting variety
Authors. Published as wellB.V.
by Elsevier as to be able to product structure on a physical level (components level) which
This is an open
identify access article
possible under the CCpotentials
optimization BY-NC-ND license
in the(http://creativecommons.org/licenses/by-nc-nd/4.0/)
existing causes difficulties regarding an efficient definition and
2212-8271
Peer-review©under
2019responsibility
The Authors. ofPublished by Elsevier
the scientific B.V.of the 53rd CIRP Conference
committee on Manufacturing Systems
production system, it is important to have a precise knowledge comparison of different product families. Addressing this
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review under responsibility of the scientific committee of the 53rd CIRP Conference on Manufacturing Systems
2212-8271 © 2020 The Authors. Published by Elsevier B.V.
This is an©open
2212-8271 2017access article Published
The Authors. under theby CC BY-NC-ND
Elsevier B.V. license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review
Peer-review under
under responsibility
responsibility of scientific
of the the scientific committee
committee of the of theCIRP
28th 53rdDesign
CIRP Conference
Conference2018.
on Manufacturing Systems
10.1016/j.procir.2020.04.086
996
kanban
Optimization of the disassembly, Minimize inventory holding cost, Stochastic lead time and
Stochastic Numerical study (two-level
[13] remanufacturing and assembly remanufacturing cost, disposal cost, quality of remanufactured Genetic algorithm
programing components)
system purchasing cost and backlogging cost components
AMPL programming
Design a modular product platform Minimize the number of assembly Mixed integer The base module of the
[14] language, & CPLEX
configuration model stations and cycle time programing modular phone
solver
Kai Kang et al. / Procedia CIRP 93 (2020) 995–1000 997
Author name / Procedia CIRP 00 (2019) 000–000 3
such as spaces, machinery and technical supporting team. Thus, approach is not suitable for our motivated case company due to
there are only few depots where can support the maintenance the limited warehouse space.
operations which are commonly regarded as disassembly and Once inspection is completed, type II parts are repaired and
assembly problems from the literature for optimization assembly plan will be executed to replace type III parts and
purposes. assemble subway cars. In such case, assembly can be
There are many research papers from literature talking about completed without any delays of all required parts. Therefore,
the disassembly and assembly of heavy-duty equipment. Table the integrated decision-making plays an important role in
1 summarizes some typical articles by considering the focused ensuring the final assembly.
problems, objective functions, factors, problem categories The major challenge faced by the company is the limited
(linear or nonlinear), solutions, solver, and practical cases. It storage space for inventory. This paper develops an integrated
could be observed that most of the research focuses on the strategy that combines disassembly and assembly planning into
maximization of profit. Integer programming is typically a single mathematical model. Inspection phase will be omitted
treated as the category from Table 1. However, there is a in this paper using fixed time horizon for presentation. The
research gap that few studies took the maintenance procedures number of required spare parts is regarded as uncertainty sets
as a whole to investigate the total cost. In order to fulfil this that are calculated based on historical data. Hence, a robust
research gap, this paper presents a deterministic mixed integer counterpart of the single mathematical model is developed by
optimization model by considering the total operational costs a robust optimization framework to minimize the total
such as purchasing cost and repair cost. A case study from HK operation cost consisting of purchasing cost and repair cost.
MTR is demonstrated to validate the proposed model. The novelties of this paper include: (i) most research focuses
The rest of this paper is organized as follows. Section 2 on continuous maintenance [15], prescriptive maintenance [16],
gives the problem description from the real-world problem opportunistic maintenance [17], and preventative maintenance,
given the case from HK MTR. Section 3 talks about the model while little research pays attention to complete maintenance; (ii)
formulation with the notifications and a deterministic mixed an integrated strategy is proposed to consider all phases when
integer optimization model considering the total costs. Section complete maintenance planning is made.
4 illustrates a case study from a real-life company in HK.
Section 5 concludes this paper by giving the key observations
and future research directions.
2. Problem Description
Table 2. Input parameters objective function for minimizing the cost from practice
Input data
ݐ concerns.
1 2 3 4 Future research directions will be conducted in the
ܦ௧ 4 3 1 0
following aspects. On one hand, the above two costs will be
ܣ௧ 0 1 3 4
ܿ௧ଵ 3 3 2 4 considered in different scenarios with different weights. How
ܿ௧ଶ 6 5 3 4 to extend this proposed model for facing more generic
ܿ௧ଷ 3 4 3 3 situations will be further investigated. On the other hand, this
௧ଵ 10 11 10 11
௧ଶ 15 12 13 17
model could be integrated into some decision-making systems
௧ଷ 13 12 16 17 such as production planning and scheduling. That will be
implemented in the near future. Finally, the inventory holding
Table 3. The number of each type of parts disposed in each subway car cost is not considered in this paper as it is one of the significant
ܫ factors which should be concerned due to the limited space for
ܬ
E1 E2 E3 E4 E5 E6 E7 holding required components. For practical concern, this is
P1 1 2 3 1 3 2 1 with great merit due to the large volume of components from
P2 2 3 1 2 3 3 4 subway cars so that the space requirement for holding these
P3 2 3 1 3 2 1 5 parts such as trucks and wheels are necessarily considered in
the future.
The detailed disassembly and assembly planning is shown
in Table 4, where capital letter D denotes disassembly and Acknowledgements
capital letter A denotes assembly. Table 5 shows the detailed
number of each type of parts that are required to be reused and This work was supported in part by the Seed Fund for Basic
procured. The total cost is 2040. Research in HKU under Grant 201906159001, and in part by
HKU KE Impact Project Scheme under Grant KE-IP-2019/20-
Table 4. The disassembly and assembly plan 31.
ݐ
ܫ References
E1 E2 E3 E4 E5 E6 E7
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