Abstract
It is imperative for manufacturing systems to improve production quality not only to maintain profitability, market share and competitiveness, but also to reduce energy waste resulted from defective items. Although quality and energy saving have attracted extensive attention in the past few decades, there is little research effort devoted to a systematic understanding of their intersection. Therefore, this paper analyzes the energy usage of a multistage production system with quality control. The Geometric reliability and Bernoulli quality models are assumed. A Markov process model is established to predict the dynamics of the production system. The energy economics of the production system are analyzed to include both production and energy cost. The optimal PWQ (Production with Quality Inspection) machine allocation method and the cost-effectiveness analysis method are formulated to increase the profit. According to the computational experiments, the proposed optimal PWQ machine allocation method can effectively reduce energy consumption. In addition, pay-back period (PBP) is an effective indicator which helps production managers make cost effective decisions for machine replacement. The research results in an in-depth understanding of the energy economics of systems with quality control, which is necessary for manufacturers to gain competitiveness with better product quality and higher energy efficiency.
Highlights
Sustainable manufacturing has become more prevalent for manufacturing companies in response to dramatic climate change, unsecured energy supply, and fluctuating energy prices
The rest of the paper is demonstrated as follows: literature review is investigated in Section II; Section III describes the assumptions and background; a Markov chain model is presented in Section IV; Section V proposes two joint quality and energy decision-making algorithms; computational experiments are performed in Section VI; Section VII summarizes the conclusions and future work
The research depicts the complex interconnection among production, quality flow and energy consumption in multistage production systems
Summary
Sustainable manufacturing has become more prevalent for manufacturing companies in response to dramatic climate change, unsecured energy supply, and fluctuating energy prices. The energy waste resulted from a defective product is not a simple summation of the energy consumption at each manufacturing stage [7] It should take into consideration of its impact on the production of the entire system [8]. Li: Energy Economics in Multistage Manufacturing Systems With Quality Control that machines waste a significant amount of production time on unidentified defective products. It is essential to have a systematic understanding of the energy consumption in multistage production systems with quality control, and establish a method to reduce the energy waste. The first problem is to establish an integrated model to analyze the production and energy consumption in a multistage production system with quality control. The rest of the paper is demonstrated as follows: literature review is investigated in Section II; Section III describes the assumptions and background; a Markov chain model is presented in Section IV; Section V proposes two joint quality and energy decision-making algorithms; computational experiments are performed in Section VI; Section VII summarizes the conclusions and future work
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