Planning and control of rework in the process industries: A review

For all kinds of reasons, rework, i.e. the transformation of products not fulfilling preset specifications into products that do, is an important issue in process industries. Despite a considerable amount of published research on planning and control of rework, and in addition many papers referring to the existence of rework in the process industries, hardly any attention has been paid to the consequences of many process industries specific characteristics for execution, planning and control of rework operations. Here are identified the characteristics of the process industries that influence the possibilities for rework in these industries, based on a framework provided by Flapper and Jensen ( International Journal of Production Research , 1999, to be published). How the available operations management literature assists in determining operational strategies for planning and control of rework in process industries is assessed. It is concluded that many relevant and interesting problems have not been addressed.

[1]  Dirk Schürbüscher,et al.  Besondere Anforderungen an die Produktionsplanung und -steuerung in der chemischen und pharmazeutischen Industrie , 1992 .

[2]  Anne Spence Wein,et al.  Random Yield, Rework and Scrap in a Multistage Batch Manufacturing Environment , 1992, Oper. Res..

[3]  Han Hoogeveen,et al.  Scheduling multipurpose batch process industries with no-wait restrictions by simulated annealing , 2000, Eur. J. Oper. Res..

[4]  Christopher S. Tang,et al.  Optimal batch sizing and repair strategies for operations with repairable jobs , 1995 .

[5]  Peng Huang,et al.  Stochastic Models in Reliability , 1999, Technometrics.

[6]  John O. McClain,et al.  The good, the bad and the ugly: Quality on an assembly line , 1990 .

[7]  Z T Balkhi.  On the optimal production stopping and restarting times for an EOQ model with deteriorating items , 2000, J. Oper. Res. Soc..

[8]  Christopher S. Tang,et al.  Optimal operating policy for a bottleneck with random rework , 1995 .

[9]  Vincent A. Mabert,et al.  Cyclical schedules for capacitated lot sizing with dynamic demands , 1991 .

[10]  Giri Kumar Tayi,et al.  An integrated production-inventory model with reprocessing and inspection , 1988 .

[11]  Tarun Gupta,et al.  Looping in a multistage production system , 1984 .

[12]  Fred Raafat,et al.  Survey of Literature on Continuously Deteriorating Inventory Models , 1991 .

[13]  V. Sridharan,et al.  A hierarchical approach for capacity coordination in multiple products single-machine production systems with stationary stochastic demands , 1995 .

[14]  Simme Douwe P. Flapper,et al.  Logistic planning and control of reworking perishable production defectives , 2001 .

[15]  Günter Fandel.  Surplus or disposal quantities in optimal program planning in joint production , 1987 .

[16]  Steven Nahmias,et al.  Perishable Inventory Theory: A Review , 1982, Oper. Res..

[17]  J. Will M. Bertrand,et al.  Evaluation of three production planning procedures for the use of recipe flexibility , 1999, Eur. J. Oper. Res..

[18]  J. Will M. Bertrand,et al.  The performance of workload rules for order acceptance in batch chemical manufacturing , 2000, J. Intell. Manuf..

[19]  Ron S. Kenett,et al.  The impact of defects on a process with rework , 1995 .

[20]  Josef Kallrath,et al.  Mixed-Integer Nonlinear Programming Applications , 1999 .

[21]  Richard M. Feldman,et al.  Optimization of process improvement and inspection location for serial manufacturing , 1996 .

[22]  Stefan Helber,et al.  Decomposition of unreliable assembly/disassembly networks with limited buffer capacity and random processing times , 1998, Eur. J. Oper. Res..

[23]  Jc Jan Fransoo,et al.  A Typology of Production Control Situations in Process Industries , 1994 .

[24]  Whm Wenny Raaymakers,et al.  Order acceptance and capacity loading in batch process industries , 1999 .

[25]  Ali M. Zargar,et al.  Effect of rework strategies on cycle time , 1995 .

[26]  R. Uzsoy,et al.  Production planning for companies with remanufacturing capability , 1995, Proceedings of the 1995 IEEE International Symposium on Electronics and the Environment ISEE (Cat. No.95CH35718).

[27]  Sung-Hoon Hong,et al.  Economic design of screening procedures when the rejected items are reprocessed , 1998, Eur. J. Oper. Res..

[28]  Rainer Kleber,et al.  Reverse logistics in a pharmaceutical company: a case study , 2003 .

[29]  Hau L. Lee,et al.  Lot sizing to reduce capacity utilization in a production process with defective items, process corrections, and rework , 1992 .

[30]  Karl Inderfurth,et al.  Analysis of MRP Policies with Recovery Options , 1999 .

[31]  In-Beum Lee,et al.  Optimal Scheduling of Multiproduct Batch Processes for Various Intermediate Storage Policies , 1996 .

[32]  Gabriel R. Bitran,et al.  Co-Production Processes with Random Yields in the Semiconductor Industry , 1994, Oper. Res..

[33]  Bong Jin Yum,et al.  Optimal inspection policies in a serial production system including scrap rework and repair: an MILP approach , 1987 .