Research Papers

Opportunity Window for Energy Saving and Maintenance in Stochastic Production Systems

[+] Author and Article Information
Jing Zou

Department of Mechanical Engineering,
Stony Brook University,
156A Light Engineering,
Stony Brook, NY 11794
e-mail: jing.zou@stonybrook.edu

Jorge Arinez

Manufacturing Systems Research Lab,
General Motors Research
and Development Center,
30500 Mound Road,
Warren, MI 48090
e-mail: jorge.arinez@gm.com

Qing Chang

Department of Mechanical Engineering,
Stony Brook University,
163 Light Engineering,
Stony Brook, NY 11794
e-mail: qing.chang@stonybrook.edu

Yong Lei

State Key Laboratory of Fluid Power Transmission and Control,
Department of Mechanical Engineering,
Zhejiang University,
Hangzhou 310013, China
e-mail: ylei@zju.edu.cn

1Corresponding author.

Manuscript received August 17, 2015; final manuscript received May 19, 2016; published online August 5, 2016. Assoc. Editor: Jianjun Shi.

J. Manuf. Sci. Eng 138(12), 121009 (Aug 05, 2016) (9 pages) Paper No: MANU-15-1425; doi: 10.1115/1.4033757 History: Received August 17, 2015; Revised May 19, 2016

Energy efficiency improvement and timely preventive maintenance (PM) are critical in manufacturing industry due to the rising energy cost, environmental concerns, and increasing requirements on system reliability. By strategically turning appropriate machines in down state, the corresponding energy consumption can be reduced, and at the meantime, the necessary PM works can be carried out to increase PM completion rate and reduce potential extra expense on PM during nonproduction shifts. However, there is usually a tradeoff between time dedicated to production and time available for energy saving and PM. In this paper, a systematic method is developed to identify opportunity windows (OWs) during which certain machines can be shut down to save energy and PM tasks can be performed while maintaining a desired production throughput. The method is based on stochastic serial production lines and real-time production data. A profit function is formulated to illustrate the tradeoff between energy cost savings and potential throughput loss. The profit function is used to justify the cost savings by utilizing the proposed OWs during production operation.

Copyright © 2016 by ASME
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Grahic Jump Location
Fig. 1

A serial production line with M machines and M−1 buffers

Grahic Jump Location
Fig. 2

The line segment between the machines Mi and M* when i<M*

Grahic Jump Location
Fig. 3

The serial production line in case study




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