Integrated Production, EWMA Scheme, and Maintenance Policy for Imperfect Manufacturing Systems of Bolt-on Vibroseis Equipment Considering Quality and Inventory Constraints

In recent years, the synergistic effect among production, maintenance, and quality control within manufacturing systems has garnered increasing attention in academic and industrial circles. In high-quality production settings, the real-time identification of minute process deviations holds significant importance for ensuring product quality. Traditional approaches, such as routine quality inspections or Shewhart control charts, exhibit limitations in sensitivity and response speed, rendering them inadequate for meeting the stringent requirements of high-precision quality control. To address this issue, this paper presents an integrated framework that seamlessly integrates stochastic process modeling, dynamic optimization, and quality monitoring. In the realm of quality monitoring, an exponentially weighted moving average (EWMA) control chart is employed to monitor the production process. The statistic derived from this chart forms a Markov process, enabling it to more acutely detect minor shifts in the process mean. Regarding maintenance strategies, a state-dependent preventive maintenance (PM) and corrective maintenance (CM) mechanism is introduced. Specifically, preventive maintenance is initiated when the system is in a statistically controlled state and the inventory level falls below a predefined threshold. Conversely, corrective maintenance is triggered when the EWMA control chart generates an out-of-control (OOC) signal. To facilitate continuous production during maintenance activities, an inventory buffer mechanism is incorporated into the model. Building upon this foundation, a joint optimization model is formulated, with system states, including equipment degradation state, inventory level, and quality state, serving as decision variables and the minimization of the expected total cost (ETC) per unit time as the objective. This problem is formalized as a constrained dynamic optimization problem and is solved using the genetic algorithm (GA). Finally, through a case study of the production process of vibroseis equipment, the superiority of the proposed model in terms of cost savings and system performance enhancement is empirically verified.