Abstract
Many studies reveal that integrating the concepts of production, maintenance and quality control helps reduce costs compared to studying them separately. But almost all the research works in this field are centred on piece part manufacturing. This paper presents an integrated model of the three concepts for the continuous flow process of manufacturing which is vastly different from piece-parts processes, as there is no explicit production unit. To quickly detect the assignable cause occurrence, an adaptive X̄ control chart with variable sampling interval designed for the continuous flow process is employed as the quality control tool. A mathematical definition is presented to describe the proposed model before a genetic algorithm is developed to find the optimal setting values of decision parameters that minimize the expected total cost per unit time. The numerical comparison indicates that the proposed model has reduced the cost by an average of 1.5% than the classical model with fixed sampling interval policy in continuous flow manufacturing. Finally, Taguchi’s design of experiments (DOE) is employed to investigate the main effects of cost and process parameters.
Published Version
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