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This research presents simultaneous design of production planning, maintenance strategy and control chart in which two issues are considered: (1) multiple assignable cause and (2) equipment failure. The first one means that various factors may shift the process to an out-of-control state; while the second one means that the equipment is not always available and may be suddenly failed. Also, to reduce the production costs, a rework process is performed on the nonconforming items right after the regular cycle. Furthermore, three types of maintenance activities are applied based on system conditions. The corrective maintenance is conducted when the equipment failure occurs. The preventive maintenance is accomplished when the process continues until the end of the cycle, and the predictive maintenance is performed whereas the chart issues a true alarm. To check the effectiveness of the model, three comparative studies are examined. The first one compares the suggested model with a similar model without the rework process; the second one demonstrates the importance of employing the statistical process monitoring; and the last one compares the model with a similar model without considering the equipment failure. The results show the superiority of the integrated model compared to the others in the cost-saving.

A production-inventory model under quality-maintenance policy with rework process in the presence of random failures and multiple assignable causes