Abstract
The proposed model focuses on an imperfect production process (IPP) in which, during long-term production, the system may change to an “out-of-control” state from an “in-control” state and produce some imperfect products because of a long production run length. Brand image and industry reputation are affected by product defectiveness. To increase the profit of any industry and improve reputation and brand image, inspection of the production system is required. However, this inspection is subjected to human error, which negatively affects the assessment of production systems. Herein, an error-free inspection is performed with the help of an autonomation policy, in which each product is inspected via a machine instead of a human, facilitating an error-free inspection and converting the production system to a smart production system. Moreover, in reality, product demand cannot always be constant. Therefore, in this model, a selling-price-dependent demand is considered along with a variable production rate to enhance model applicability. Moreover, total system profit is optimized and optimal values for production run time, inspection scheduling, selling price, buffer inventory, and production rate are determined. Finally, for model validation, some numerical examples along with special cases are provided. The concavity of the optimal function is also proven through graphical illustration. The sensitivity of the key parameters of the presented model is explored and the significance is explained.
Highlights
By the industrial revolution, several improved changes are coming continiously through the industry 4.0 (Angelopoulou et al [1], Bueno et al [2], Ghosh et al [3]), and numerous researchers are constantly attempting to improve their models by developing novel and different technological strategies
To maintain the brand image and maximize the total system profit, process and product quality inspections are necessary for any imperfect production process (IPP)
The aim of the current study is to develop a smart production process where the autonomation policy instead of human inspection is adopted, i.e., the entire system is controlled by a machine and not by humans, which makes the process smarter and allows the system to manufacture a defect-free product
Summary
Several improved changes are coming continiously through the industry 4.0 (Angelopoulou et al [1], Bueno et al [2], Ghosh et al [3]), and numerous researchers are constantly attempting to improve their models by developing novel and different technological strategies. It is quite natural that, when a production system run over a long time, due to different issues, it may produce defective or imperfect items. If those imperfect products deliver to customers, the reputation of the company gradually decreases, which directly hampers the profit of the company. The aim of the current study is to develop a smart production process where the autonomation policy instead of human inspection is adopted, i.e., the entire system is controlled by a machine and not by humans, which makes the process smarter and allows the system to manufacture a defect-free product. It is proven that the item profit is maximized and the optimal values for buffer inventory, production rate, selling price, and investment for autonomation are determined. The time for starting the inspection process for optimal profit is achieved in this study
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