| Production costs account for the largest share of the overall cost of manufacturing facilities. With the U.S. industrial sector becoming more and more competitive, manufacturers are looking for more cost and resource efficient working practices. Operations management and production planning have shown their capability to dramatically reduce manufacturing costs and increase system robustness. When implementing operations related decision making and planning, two fields that have shown to be most effective are maintenance and energy. Unfortunately, the current research that integrates both is limited. Additionally, these studies fail to consider parameter domains and optimization on joint energy and maintenance driven production planning.;Accordingly, production planning methodology that considers maintenance and energy is investigated. Two models are presented to achieve well-rounded operating strategy. The first is a joint energy and maintenance production scheduling model. The second is a cost per part model considering maintenance, energy, and production. The proposed methodology will involve a Time-of-Use electricity demand response program, buffer and holding capacity, station reliability, production rate, station rated power, and more. In practice, the scheduling problem can be used to determine a joint energy, maintenance, and production schedule. Meanwhile, the cost per part model can be used to: (1) test the sensitivity of the obtained optimal production schedule and its corresponding savings by varying key production system parameters; and (2) to determine optimal system parameter combinations when using the joint energy, maintenance, and production planning model.;Additionally, a factor analysis on the system parameters is conducted and the corresponding performance of the production schedule under variable parameter conditions, is evaluated. Also, parameter optimization guidelines that incorporate maintenance and energy parameter decision making in the production planning framework are discussed. A modified Particle Swarm Optimization solution technique is adopted to solve the proposed scheduling problem. The algorithm is described in detail and compared to Genetic Algorithm. Case studies are presented to illustrate the benefits of using the proposed model and the effectiveness of the Particle Swarm Optimization approach.;Numerical Experiments are implemented and analyzed to test the effectiveness of the proposed model. The proposed scheduling strategy can achieve savings of around 19 to 27 % in cost per part when compared to the baseline scheduling scenarios. By optimizing key production system parameters from the cost per part model, the baseline scenarios can obtain around 20 to 35 % in savings for the cost per part. These savings further increase by 42 to 55 % when system parameter optimization is integrated with the proposed scheduling problem. Using this method, the most influential parameters on the cost per part are the rated power from production, the production rate, and the initial machine reliabilities.;The modified Particle Swarm Optimization algorithm adopted allows greater diversity and exploration compared to Genetic Algorithm for the proposed joint model which results in it being more computationally efficient in determining the optimal scheduling. While Genetic Algorithm could achieve a solution quality of $ 2,279.63 at an expense of 2,300 seconds in computational effort. In comparison, the proposed Particle Swarm Optimization algorithm achieved a solution quality of $ 2,167.26 in less than half the computation effort which is required by Genetic Algorithm. |
