Optimal decision-making for a single-stage manufacturing system with rework options

Abstract

ABSTRACTThis study investigates a manufacturing system with a single-stage production system that sometimes produces imperfect items. In this system, we assume that the rework process can start after the regular production process (immediate rework) or when the inventory of perfect goods is equal to zero (delayed rework). Also, we assumed non-zero set-up time for rework. Two models are presented for manufacturing systems with re-workable goods. The first model deals with non-zero set-up time for immediate rework and the second model deals with non-zero set-up times for delayed rework. We also investigate special cases associated with these models wherein the set-up times are zero. A general and aggregated model that included those two models is considered. The novelty of this research lies in selecting for a decision-maker the best approach based on system conditions and solutions. This paper provides a framework for rework policies to minimise the total cost of the system, which includes the cost of manufacturing cost, set-up cost for rework and regular production, holding cost for perfect and imperfect items, and the cost of rework. Finally, we solve the aggregated model by using an exact solution algorithm, and the optimal value of production in each period is obtained.