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This paper proposes an integrated framework for maintenance, spare parts ordering, and quality control planning within a multi-state production system that is subject to two competing modes of failure: hard failure and soft failure. Hard failures occur suddenly and without any prior warning, whereas soft failures develop following the onset of a defect. The quality of the product is significantly influenced by the state of the system, as a defective system typically leads to an increase in non-conforming products. To address this, periodic inspections are conducted to detect defects early, and preventive replacements (PR) are scheduled upon identification of a defective state, which acts as a crucial quality control indicator. Corrective replacements (CR) become necessary when either a hard or soft failure occurs. The timeliness of these replacements is contingent upon spare part availability; thus, we implement a hybrid spare ordering policy to enhance responsiveness. PR and CR are executed promptly when time-based ordered spares are accessible, while a condition-based order is triggered in the event of shortages in time-based orders. To determine the optimal inspection interval and time-based spare ordering point, we analyze the renewal scenarios of the system with the objective of minimizing the expected cost rate. We propose an optimization algorithm and a simulation procedure to validate the effectiveness of our policy through numerical experiments. The results highlight the significant potential of our approach in reducing unit losses related to non-conforming products while effectively minimizing the expected cost rate.
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PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART O-JOURNAL OF RISK AND RELIABILITY
ISSN: 1748-006X
Year: 2025
2 . 1 0 0
JCR@2022
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ESI Highly Cited Papers on the List: 0 Unfold All
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30 Days PV: 5
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