Abstract
Each industry prefers to sell perfect products in order to maintain its brand image. However, due to a long-run single-stage production system, the industry generally obtains obstacles. To solve this issue, a single-stage manufacturing model is formulated to make a perfect production system without defective items. For this, the industry decides to stop selling any products until whole products are ready to fulfill the order quantity. Furthermore, manufacturing managers prefer product qualification from the inspection station especially when processes are imperfect. The purpose of the proposed manufacturing model considers that the customer demands are not fulfilled during the production phase due to imperfection in the process, however customers are satisfied either at the end of the inspection process or after reworking the imperfect products. Rework operation, inspection process, and planned backordering are incorporated in the proposed model. An analytical approach is utilized to optimize the lot size and planned backorder quantities based on the minimum average cost. Numerical examples are used to illustrate and compare the proposed model with previously developed models. The proposed model is considered more beneficial in comparison with the existing models as it incorporates imperfection, rework, inspection rate, and planned backorders.
Highlights
Economic and production order quantity models have been extensively used in real industrial life for calculation of the optimum lot size
Products are not delivered directly to the customer as observed in most of the conventional production order quantity models. This model optimized the lot size and backorder quantity in an imperfect manufacturing setup when demands are fulfilled after the production process
This approach is against the conventional production order quantity models where processes are imperfect and demands are fulfilled simultaneously
Summary
Economic and production order quantity models have been extensively used in real industrial life for calculation of the optimum lot size. Manufacturing processes involved in ultra-precision manufacturing industries including the automobile sector, ship manufacturing, defense and aerospace related products manufacturing industries, and tool manufacturing industries are a few of the common areas where the production of reworked and non-reworked products cannot be eliminated at all Such products need qualification from the quality control department of the said organization in order to ensure that the product has been manufacturing as per customer requirements. In such setups, it is very rare that the product is delivered without its confirmation from inspection stations, i.e., demands fulfillment during the production stage.
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