Integrated model of quality inspection, preventive maintenance and buffer stock in an imperfect production system

Abstract In this study, the influence of a quality inspection policy on an imperfect production system in which a percentage of the produced items is inspected is modelled. The inspection policy is imperfect, permitting type I and type II errors. Items are shipped for sale with a free minimal repair warranty policy. After each production cycle, preventive maintenance is performed. In case of failure in the production process before the cycle’s end, a minimal repair is indicated. A buffer stock is established to meet demand while preventive maintenance is performed. We also considered that defective items detected on inspection are sent for reworking. The model is formulated with the objective of minimizing the total cost expected per item while considering an average outgoing quality constraint. Subsequently, we present a numerical experiment to illustrate the proposed model. The results indicate that the probability of type I and type II inspection errors has a significant impact on optimal production and the percentage of items inspected.

[1]  Ling Li,et al.  Integrated production, quality control and condition-based maintenance for imperfect production systems , 2018, Reliab. Eng. Syst. Saf..

[2]  Chih-Hsiung Wang.  Integrated production and product inspection policy for a deteriorating production system , 2005 .

[3]  Abdur Rahim,et al.  Integrated models in production planning and scheduling, maintenance and quality: a review , 2012 .

[4]  Mohammed Ben‐Daya,et al.  Effect of inspection errors and preventive maintenance on a two-stage production inventory system , 2007 .

[5]  Robert Pellerin,et al.  Integrated production, sampling quality control and maintenance of deteriorating production systems with AOQL constraint , 2016 .

[6]  Velusamy Subramaniam,et al.  Joint control of dynamic maintenance and production in a failure-prone manufacturing system subjected to deterioration , 2018, Comput. Ind. Eng..

[7]  Shey-Huei Sheu,et al.  Production , Manufacturing and Logistics Optimal economic production quantity policy for imperfect process with imperfect repair and maintenance , 2008 .

[8]  D. N. P. Murthy,et al.  Warranty servicing strategies to improve customer satisfaction , 2004 .

[9]  Ieke le Blanc,et al.  Product Modularity and the Design of Closed-Loop Supply Chains , 2004 .

[10]  Shib Sankar Sana,et al.  Preventive maintenance and optimal buffer inventory for products sold with warranty in an imperfect production system , 2012 .

[11]  Mustapha Nourelfath,et al.  Integrated preventive maintenance and production decisions for imperfect processes , 2016, Reliab. Eng. Syst. Saf..

[12]  Shey-Huei Sheu,et al.  Determining the optimal production-maintenance policy with inspection errors: using a Markov chain , 2003, Comput. Oper. Res..

[13]  Bibhas C. Giri,et al.  Production lot sizing with process deterioration and machine breakdown under inspection schedule , 2009 .

[14]  Randolph Kirchain,et al.  Cost of quality: Evaluating cost-quality trade-offs for inspection strategies of manufacturing processes , 2017 .

[15]  Sai Ho Chung,et al.  A Stochastic Production-Inventory Model in a Two-State Production System With Inventory Deterioration, Rework Process, and Backordering , 2017, IEEE Transactions on Systems, Man, and Cybernetics: Systems.

[16]  Hong-Fwu Yu,et al.  AN OPTIMAL POLICY FOR CSP-1 WITH INSPECTION ERRORS AND RETURN COST , 2009 .

[17]  Mohamed Ben-Daya,et al.  The economic production lot-sizing problem with imperfect production processes and imperfect maintenance , 2002 .