Integrated optimisation of production scheduling, maintenance, and quality control under non-homogeneous poisson process failures with multiple assignable causes

Manufacturing optimisation often treats production scheduling, equipment maintenance, and statistical process control as independent entities, despite their inherently dependent nature. This paper proposes an integrated optimisation approach that simultaneously addresses these factors for enhanced decision-making. By considering non-homogeneous Poisson process failures and the influence of assignable causes, our framework evaluates possible scenarios within a production cycle and estimates expected cycle length and cost as well as the expected job completion time. The model optimises expected total costs, including those related to quality, maintenance, and penalties for late deliveries, while ensuring efficient production through equipment availability and constraint on maximum delay. We demonstrate the effectiveness of this approach through numerical studies, sensitivity analyses, and two real-world case studies: one in the food production industry and another in the automotive parts manufacturing industry based on the assumed data. In both cases, the model integrates production scheduling, maintenance, and quality control to minimise costs and ensure timely delivery. These case studies showcase this research's contribution to the development of more resilient and efficient manufacturing systems.