A periodic review production and maintenance model with random demand, deteriorating equipment, and binomial yield

In many environments, product yield is heavily influenced by equipment condition. Despite this fact, previous research has either focused on the issue of maintenance, ignoring the effect of equipment condition on yield, or has focused on the issue of production, omitting the possibility of actively changing the machine state. We formulate a Markov decision process model of a single-stage production system in which demand is random. The product yield has a binomial distribution that depends on the equipment condition, which deteriorates over time. The objective is to choose simultaneously the equipment maintenance schedule as well as the quantity to produce in a way that minimizes the sum of expected production, backorder, and holding costs. After proving some results about the structural properties of the optimal policy, numerical problems are used to compare this method to the typical approach of solving the maintenance and production problems sequentially. The results show that the simultaneous solution provides substantial gains over the sequential approach. In the cases studied, the proposed method resulted in an average cost savings of approximately 18%. Journal of the Operational Research Society (2004) 55, 647–656. doi:10.1057/palgrave.jors.2601725