Abstract
The present study explores the collective influence of component commonality, adjustable-rate, postponement, and rework on the multi-item manufacturing decision. In contemporary markets, customer demand trends point to fast-response, high-quality, and diversified merchandise. Hence, to meet customer expectations, modern manufacturers must plan their multiproduct fabrication schedule in the most efficient and cost-saving way, especially when product commonality exists in a series of end products. To respond to the above viewpoints, we propose a two-stage multiproduct manufacturing scheme, featuring an adjustable fabrication rate in stage one for all needed common parts, and manufacturing diversified finished goods in stage two. The rework processes are used in both stages to repair the inevitable, nonconforming items and ensure the desired product quality. We derive the cost-minimized rotation cycle decision through modeling, formulation, cost analysis, and differential calculus. Using a numerical illustration, we reveal the collective and individual influence of adjustable-rate, rework, and postponement strategies on diverse critical system performances (such as uptime of the common part and/or end products, utilization, individual cost factor, and total system cost). Our decision-support model offers in-depth managerial insights for manufacturing and operations planning in a wide variety of contemporary industries, such as household merchandise, clothing, and automotive.
Highlights
This study develops a decision-support model to explore the collective impact of component commonality, adjustable-rate, postponement, and rework on the multi-item manufacturing decision.To satisfy customer orders of product diversity and fast response, manufacturing firms seek the most cost-effective and rapid manufacturing scheme, such as a delayed product differentiation approach to fabricate a series of goods that contain commonality in these end products
As few past studies have concentrated on exploring the collective and individual impact of product commonality, adjustable-rate, postponement, and rework on multi-item manufacturing decision-making, this study aims to address the aforementioned subject
Suppose five different end products that share a common part must be produced by a two-stage fabrication scheme with a postponement strategy
Summary
This study develops a decision-support model to explore the collective impact of component commonality, adjustable-rate, postponement, and rework on the multi-item manufacturing decision. The authors derived the cost-minimized production plan under service level constraints, random failure, and variable fabrication rates They further extended the model by incorporating a preventive maintenance policy to examine its impact on the optimal fabrication plan. The authors treated the fabrication rate as a decision variable and presented a solution approach for their proposed single-producer single-customer integrated model with an exponentially deteriorating product They used a numerical example to provide the minimum cost operating plan for the problem and showed that their results outperformed the same model with a fixed fabrication rate. Our decision-support model offers in-depth managerial insights for manufacturing and operations planning in various contemporary industries, such as household merchandise, clothing, and automotive
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