Optimal Production and Inspection Strategy with Inspection Time and Reworking for a Deteriorating Process

 The paper considers an integrated production, inspection, preventive maintenance, and inventory problem and determines the optimal inspection interval, inspection frequency, and production quantity yielding the maximum unit expected profit in an imperfect production process with inspection time and reworking. When the process in an out-of-control state produces a certain percentage of non-conforming items, this study assumes that a certain proportion of the non-conforming items can be reworked into conforming items. Furthermore, in a system with process deterioration, this study examines the effectiveness of imperfect preventive maintenance, and conducts numerical analysis to explore the influence of reworking and inspection time on profit. Keywords inventory, preventive maintenance, imperfect rework, imperfect process, inspection time

[1]  H. Pham,et al.  Invited reviewImperfect maintenance , 1996 .

[2]  Jean-Pierre Kenné,et al.  Optimal production, maintenance and lockout/tagout control policies in manufacturing systems , 2007 .

[3]  Bhaba R. Sarker,et al.  Optimal batch quantity models for a lean production system with in-cycle rework and scrap , 2008 .

[4]  M. K. Salameh,et al.  Economic production quantity model for items with imperfect quality , 2000 .

[5]  M. Ben-Daya Integrated production maintenance and quality model for imperfect processes , 1999 .

[6]  Singa Wang Chiu,et al.  Optimal production lot sizing with rework, scrap rate, and service level constraint , 2007, Math. Comput. Model..

[7]  Douglas J. Thomas,et al.  The value of setup cost reduction and process improvement for the economic production quantity model with defects , 2006, Eur. J. Oper. Res..

[8]  Graham K. Rand,et al.  Decision Systems for Inventory Management and Production Planning , 1979 .

[9]  Sheng-Tsaing Tseng,et al.  Imperfect maintenance policies for deteriorating production systems , 1998 .

[10]  Yan Chun Chen,et al.  Economic optimisation for an imperfect production system with rework and scrap rate , 2010 .

[11]  Bhaba R. Sarker,et al.  Optimal batch sizing in a multi-stage production system with rework consideration , 2008, Eur. J. Oper. Res..

[12]  P. A. Hayek,et al.  Production lot sizing with the reworking of imperfect quality items produced , 2001 .

[13]  M. A. Rahim,et al.  Economic design of x -control charts under Weibull shock models , 1988 .

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

[15]  M. Darwish EPQ models with varying setup cost , 2008 .

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

[17]  Y. Chiu Determining the optimal lot size for the finite production model with random defective rate, the rework process, and backlogging , 2003 .

[18]  Mohamad Y. Jaber,et al.  Lot sizing for an imperfect production process with quality corrective interruptions and improvements, and reduction in setups , 2006, Comput. Ind. Eng..

[19]  Hsu-Hua Lee,et al.  The investment model in preventive maintenance in multi-level production systems , 2008 .

[20]  M Ben-Daya,et al.  Integrated production and quality model under various preventive maintenance policies , 1998, J. Oper. Res. Soc..