An imperfect multi-item single-machine production system with shortage, rework, and scrap considering inspection, dissimilar deficiency levels, and non-zero setup times

Document Type : Article

Authors

1 Faculty of Industrial and Mechanical Engineering, Qazvin Branch, Islamic Azad University, Qazvin, Iran

2 Information Science, University of Otago, Dunedin, New Zealand

3 The Logistics Institute-Asia Pacific, National University of Singapore, 21 Heng Mui Keng Terrace, #04-01, Singapore 119613

4 Department of Industrial and Systems Engineering, Chung Yuan Christian University, No. 200, Chung Pei Road, Chung Li District, Taoyuan City, 32023, Taiwan

Abstract

In this paper, we consider a deficient production system with permissible shortages. The production system consists of a unique machine that manufactures a number of products that a part of them are imperfect in form of rework or scrap. These defective products are identified by 100% inspection during production, then, they are whether reworked or disposed of after normal production process. Like real-world production systems, there are diverse kinds of errors creating dissimilar breakdown severity and rework. Moreover, reworks have non-zero setup times that makes the problem closer to real-world instances where machines require some preparations before starting a new production cycle. Thus, we introduce an economic production quantity (EPQ) problem for an imperfect manufacturing system with non-zero setup times for rework items. The rework items are classified into several categories based on their type of failure and rework rate. The aim of this study is to obtain optimum production time and shortage in each period that minimizes inventory system costs including setup costs in reworks, holding costs, production costs, inspection costs, disposal costs, and shortage. Finally, a numerical example is proposed to assess efficiency and validation of the proposed algorithm.

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Main Subjects


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