Integrated Production-Maintenance Strategy considering energy consumption and recycling constraints in dry machining

Abstract The current challenge for industrial companies, involved in improving CNC - Computer Numerical Control - mechanical manufacturing machines, consists in integrating production decision aid adapted to the constraints associated with dry machining processes. This tool provides the best choice of appropriate production parameters for dry machining, which has a direct impact on productivity, system degradation and the quality of the final product. The proposed study develops an integrated production-maintenance policy which considers simultaneously several parameters related to production process and manufacturing system environment. In fact, our goal consists in determining an economical integrated production maintenance strategy that minimize the total cost including raw materials, production, recycling and maintenance. Considering two types of raw materials (steel and aluminum) and requesting to a random demand over a finite horizon dissociated to subperiods, the economical integrated maintenance-production, which is obtained by minimizing the total cost, is illustrated by the processing time of each type of raw materials for each subperiod and the optimal preventive maintenance time. The impact of the type of raw material with regard to some parameters like cutting speed, recycle cost, and the degradation system is taken into account in the determination of the economic plan. An analytical model expressing the objective function, the total cost, according to the variable decisions is developed. A numerical solving procedure, a numerical example and a sensitivity study are proposed in order to prove the developed analytical model.