Classical Economic Production Quantity Research Articles

An integrated EPQ model based on a control chart for an imperfect production process

The notion of quality control is introduced into the classic economic production quantity (EPQ) model. Based on previous research, this paper contributes to an integrated EPQ model combining the concepts of statistical process control and maintenance. An imperfect production process involving three different conditions is considered. A control chart is adopted to monitor the whole process with Taguchi's loss function estimating the quality cost of each condition. A corresponding maintenance policy is planned for the machine depending on what condition it runs in. Thus the proposed EPQ model takes quality-related costs and maintenance-related costs into account other than storage costs and ordering costs already considered in the classic model. The objective of this model is to minimise the total expected production cost per production cycle while simultaneously determining the optimal parameters of control chart design, the interval between sampling, the sample size and the maintenance decision policy. The pattern search method is used to solve the problem using the MATLAB toolbox. In addition, a case study, sensitivity analysis and comparison analysis are presented to demonstrate the application of the model.

Economic production quantity model for items with continuous quality characteristic, rework and reject

The economic production quantity (EPQ) model is a well-known and commonly used inventory control technique. However, the model is built on an unrealistic assumption that all the produced items need to be of perfect quality. Having relaxed this assumption, some researchers have studied the effects of the imperfect products on the inventory control techniques. This article, thus, attempts to develop an EPQ model with continuous quality characteristic and rework. To this end, this study assumes that a produced item follows a general distribution pattern, with its quality being perfect, imperfect or defective. The analysis of the model developed indicates that there is an optimal lot size, which generates minimum total cost. Moreover, the results show that the optimal lot size of the model equals that of the classical EPQ model in case imperfect quality percentage is zero or even close to zero.

Economic production quantity concerning learning and the reworking of imperfect items

The classical economic production quantity (EPQ) model assumes that items produced are of perfect quality and the production rate is constant. However, production quality depends on the condition of the process. Due to process deterioration or other factors, the production process may shift and produce imperfect quality items. These imperfect quality items sometimes can be reworked and repaired; hence, overall production-inventory costs can be reduced significantly. In addition, it can be found in practice that the time or cost required to repetitively produce a unit of a product decreases when the number of units produced by a worker or a group of workers increases. Under this circumstance, the unit production cost cannot be regarded as constant and, therefore, cannot be ignored when taking account of the total cost. This paper incorporates the effects of learning and the reworking of defective items on the EPQ model since they were not considered in existing models. An optimal operation policy that minimizes the expected total cost per unit time is derived. A numerical example is provided to illustrate the proposed model. In addition, sensitivity analysis is performed and discussed.

Replenishment Lot Size and Number of Shipments for EPQ Model Derived Without Derivatives

This paper investigates optimal replenishment lot size and optimal number of shipments for economic production quantity (EPQ) model with rework process using an algebraic approach. The classic EPQ model assumes a perfect quality production for all items produced and a continuous issuing policy for satisfying customer‟s demand. However, in a real life vendor-buyer integrated-production-inventory system, a multi- delivery policy is commonly used in lieu of a continuous issuing policy and generation of defective items during a production run seems to be inevitable. A recent published work examined such an identical problem using mathematical modeling and differential calculus to derive the optimal replenishment lot size and optimal number of deliveries that minimizes overall production-inventory-shipment costs. This paper proposes a straightforward algebraic approach to replace the use of calculus on the cost function for determining optimal production-shipment policies. It also presents a simpler form for calculating the long-run average cost for such an imperfect EPQ problem.

Optimal pricing, lot-sizing and marketing planning in a capacitated and imperfect production system

In the classical economic production quantity (EPQ) problem demand is considered to be known in advance. However, in the real-world, demand of a product is a function of factors such as product’s price, its quality, and marketing expenditures for promoting the product. Quality level of the product and specifications of the adopted manufacturing process also affect the unit product’s cost. Therefore, in this paper we consider a profit maximizing firm who wants to jointly determine the optimal lot-sizing, pricing, and marketing decisions along with manufacturing requirements in terms of flexibility and reliability of the process. Geometric programming (GP) technique is proposed to address the resulting nonlinear optimization problem. Using recent advances in optimization techniques we are able to optimally solve the developed, highly nonlinear, mathematical model. Finally, using numerical examples, we illustrate the solution approach and analyze the solution under different conditions.

Determining replenishment lot size and shipment policy for an extended EPQ model with delivery and quality assurance issues

This paper derives the optimal replenishment lot size and shipment policy for an Economic Production Quantity (EPQ) model with multiple deliveries and rework of random defective items. The classic EPQ model assumes a continuous inventory issuing policy for satisfying demand and perfect quality for all items produced. However, in a real life vendor–buyer integrated system, multi-shipment policy is practically used in lieu of continuous issuing policy and generation of defective items is inevitable. It is assumed that the imperfect quality items fall into two groups: the scrap and the rework-able items. Failure in repair exists, hence additional scrap items generated. The finished items can only be delivered to customers if the whole lot is quality assured at the end of rework. Mathematical modeling is used in this study and the long-run average production–inventory-delivery cost function is derived. Convexity of the cost function is proved by using the Hessian matrix equations. The closed-form optimal replenishment lot size and optimal number of shipments that minimize the long-run average costs for such an EPQ model are derived. Special case is examined, and a numerical example is provided to show its practical usage.

Joint Determination of the Production Lot Size and Number of Shipments for EPQ Model with Rework

This paper is concerned with joint determination of the optimal lot size and optimal number of shipments for an economic production quantity (EPQ) model with the reworking of random defective items produced. The classic EPQ model assumes a continuous issuing policy for satisfying product demand and perfect quality production for all items produced. However, in a real life vendor-buyer integrated-productioninventory system, a multi-delivery policy is used practically in lieu of the continuous issuing policy, and it is inevitable to generate defective items during a production run. In this study, all nonconforming items produced are considered to be repairable and are reworked in each cycle after the end of a production run. The fixed-quantity multiple installments of the finished batch can only be delivered to customers if the whole lot is quality assured at the end of the rework. Mathematical modeling is used and the longrun average integrated cost per unit time is derived. Convexity of the cost function is proved by the use of the Hessian matrix equations. A closed-form optimal productionshipment policy to the problem is obtained. A special case to the model is discussed. Finally, a numerical example is provided to demonstrate the model’s practical usage.

Determining optimal selling price and lot size with process reliability and partial backlogging considerations

In this article, we extend the classical economic production quantity (EPQ) model by proposing imperfect production processes and quality-dependent unit production cost. The demand rate is described by any convex decreasing function of the selling price. In addition, we allow for shortages and a time-proportional backlogging rate. For any given selling price, we first prove that the optimal production schedule not only exists but also is unique. Next, we show that the total profit per unit time is a concave function of price when the production schedule is given. We then provide a simple algorithm to find the optimal selling price and production schedule for the proposed model. Finally, we use a couple of numerical examples to illustrate the algorithm and conclude this article with suggestions for possible future research.

An Algebraic Approach for Determining the Optimal Lot Size for EPQ Model with Rework Process

This paper presents a simple algebraic approach for deriving the optimal lot size for economic production quantity (EPQ) model with rework process. Conventional methods for solving lot size problems are by using differential calculus on the long-run average production-inventory cost function with the need to prove optimality first. A few recent articles proposed the algebraic approach to the solution of classic economic order quantity (EOQ) and EPQ model without reference to the use of derivatives. This paper extends it to an EPQ model with reworking of defective items. We demonstrate that optimal lot size and optimal production-inventory cost for such an imperfect EPQ model can be derived without derivatives. As a result, it may enable the practitioners or students who with little knowledge of calculus to understand or handle with ease the realistic production systems.

Mathematical modelling for determining economic batch size and optimal number of deliveries for EPQ model with quality assurance

The classic economic production quantity (EPQ) model assumes a continuous inventory-issuing policy for satisfying product demand and a perfect production for all items produced. However, in a real-life vendor–buyer integrated system, a multi-delivery policy is often used in lieu of continuous issuing policy and it is inevitable to generate defective items during a production run. This study addresses these issues by incorporating multiple deliveries of the finished batch, customer's inventory-holding cost and manufacturer's quality assurance cost into an EPQ model with the imperfect reworking of random defective items. Mathematical modelling and analyses are employed. Convexity of the long-run expected cost function is proved by the use of Hessian matrix equations, and the closed-form solutions in terms of the optimal lot size and optimal number of deliveries are obtained. The research results are demonstrated with a numerical example with a discussion on its practical usage.

Economic production quantity with imperfect production processes and learning effects

The fundamental assumptions of the classical economic production quantity (EPQ) model are that the production rate is constant and 100% of items in each production lot are perfect. These assumptions are not always pertinent while learning is in progress, production process deterioration, or other factors happen. Therefore, this study investigates the effects of learning and imperfect quality items on the EPQ model. The system is assumed to deteriorate during the production process and produce some proportion of defective items. A mathematical model is derived to determine the optimal production quantity. Numerical example and sensitivity analysis are presented to illustrate important issues related to the developed model.

An EOQ model with noninstantaneous receipt and exponentially deteriorating items under two-level trade credit

This paper considers the impact of the trade credit policy on the classical Economic Production Quantity (EPQ) model for an item subject to exponential decays. Essentially, this study focuses on an exponentially deteriorating item under the conditions of the retailer receiving the supplier trade credit and providing the customer trade credit simultaneously so as to minimize the average total cost. A theorem is developed to determine the optimal replenishment policies. The main contribution to literature is the inclusion of the latter type of payment delay. Finally, through numerical examples, sensitive analysis shows the influence of key model parameters.

EPQ models with varying setup cost

In this paper, the classical economic production quantity (EPQ) model is generalized by considering a relationship between the setup cost and the production run length. The dependency between the setup cost and run length can be related to process deterioration and learning and forgetting effects. Two models are developed, the first of which is for the case when shortages are not allowed and the other one permits shortages. The cost functions associated with these models are proved to be convex and optimal solutions are determined. Results show that the relationship between setup cost and production run length has a significant impact on the optimal lot size and average total cost in the EPQ model. Numerical examples are presented to demonstrate the utility of the models.

A generalized geometric-programming solution to “An economic production quantity model with flexibility and reliability considerations”

The classical economic production quantity (EPQ) model assumes that items are produced by a perfectly reliable production process with a fixed set-up cost. While the reliability of the production process cannot be perfected cost-free, the set-up cost can be reduced by investment in flexibility improvement. In this paper, we propose an EPQ model with a flexible and imperfect production process. We formulate this inventory decision problem using geometric programming (GP), establish more general results using the arithmetic-geometric mean inequality, and solve the problem to obtain a closed-form optimal solution. Following the theoretical treatment, we provide a numerical example to demonstrate that GP has potential as a valuable analytical tool for studying a certain class of inventory control problems. Finally we discuss some aspects of sensitivity analysis of the optimal solution based on the GP approach.

On a production-inventory system of deteriorating items subject to random machine breakdowns with a fixed repair time

This paper considers the impact of random machine breakdowns on the classical Economic Production Quantity (EPQ) model for a product subject to exponential decay and under a no-resumption (NR) inventory control policy. A product is manufactured in batches on a machine that is subject to random breakdowns in order to meet a constant demand over an infinite planning horizon. The product is assumed to have a significant rate of deterioration and time to deterioration is described by an exponential distribution. Also, the time-to-breakdown is a random variable following an exponential distribution. Under the NR policy, when a breakdown occurs during a production run, the run is immediately aborted. A new run will not be started until all available inventories are depleted. Corrective maintenance of the production system is carried out immediately after a breakdown and it takes a fixed period of time to complete such an activity. The objective is to determine the optimal production uptime that minimizes the expected total cost per unit time consisting of setup, corrective maintenance, inventory carrying, deterioration, and lost sales costs. A near optimal production uptime is derived under conditions of continuous review, deterministic demand, and no shortages.

Case study: quality improvement model in a car seat assembly line

In this paper, we develop a quality improvement model based on the structure of classical economic production quantity (EPQ) model. The asymmetrical truncated loss function is used to evaluate the cost of poor quality in a production system. A practical quality improvement case which follows the 6-sigma DMAIC method in a car seat assembly line is discussed to verify the proposed model. Our model provides a fundamental structure for studying the cost of quality improvement in a production system. Based on this model, the management can evaluate the affect of quality investment to generate significant financial return in their production line.

Note on “Effects of Random Defective Rate and Imperfect Rework Process on Economic Production Quantity Model”

Conventional approaches for deriving optimal production lot size are by using the differential calculus on the production-inventory cost function with the need to prove optimality first. Recent articles proposed the algebraic approach to the solution of classic economic order quantity and economic production quantity (EPQ) model without reference to the use of derivatives. This note extends it to an EPQ model taking the random defective rate and imperfect rework process into consideration. We demonstrate that the optimal lot size can be solved algebraically and the expected inventory cost can be derived immediately as well.

Effects of random defective rate and imperfect rework process on economic production quantity model

This paper considers the economic production quantity (EPQ) model with a random defective rate and an imperfect rework process. The assumption of perfect quality production condition of the classical EPQ model is unrealistic. Due to process deterioration or other factors, production of defective items is inevitable. This study assumes that the defective rate is a random variable and all items produced are inspected. The imperfect quality items fall into two groups, the repairable and the scrap. The reworking of the repairable defective items starts when the regular production process finishes in each cycle. The rework process is also assumed to be imperfect, with a random scrap rate. Since the scrap items are produced during a production run, it follows that the production cycle length is not a constant. The renewal reward theorem is utilized to cope with the variable cycle length. A mathematical model is developed to minimize the overall costs and to derive the optimal lot size for the imperfect quality EPQ model where shortages are not permitted. A numerical example is provided to demonstrate its practical usage.

Determining the optimal lot size for the finite production model with random defective rate, the rework process, and backlogging

This paper considers the effects of the reworking of defective items on the economic production quantity (EPQ) model with backlogging allowed. The classic EPQ model assumes that manufacturing facility functions perfectly during a production run. However, due to process deterioration or other factors, the production process may shift and produce imperfect quality items. In this study, a random defective rate is considered, and when regular production ends, the reworking of defective items starts immediately. Not all of the defective items are reworked, a portion of them are scrap and are discarded. Repairing and holding cost per reworked item and disposal cost per scrap item are included in the proposed mathematical modelling and analysis. The renewal reward theorem is utilized to deal with the variable cycle length, and the optimal lot size that minimizes the overall costs for the imperfect quality EPQ model is derived where backorders are permitted.

The effect of capital lockup and customer trade credits on the optimal lot size—a confirmation of the EPQ

The classical economic production quantity (EPQ) formula, which is obtained by balancing set-up and carrying costs, is reconsidered in this paper. Since the cost of capital tied up in stocked items is the most important part of the carrying costs, a refined approach considering different components of the capital lockup, i.e. direct labour, material, and set-up costs, is presented. Furthermore, in addition to the intensively discussed supplier trade credit, the hitherto neglected customer trade credit is introduced into the analysis. A comparison of the resulting lot-size formula and the classical one indicates that the ongoing discussion about financial refinements of the EPQ might end up at its starting point given by Harris (Oper. Res. 38 (1990) 947–50), as the classical formula can be transformed into the new one by choosing the crucial carrying cost parameter adequately. Consequently, several alternative approximations for the carrying cost parameter in the EPQ are evaluated. Scope and purpose Typically, lot-size planning takes into consideration only data from the production sector. In doing this, the interdependencies between the production and the financial sector of a firm are neglected. Consequently, a recently emerging discussion intends to overcome the separation of these two firm sectors. We extend the approaches presented up to the present date by modelling capital lockup in a more detailed way considering both the supplier and the customer trade credit as well as the time structure of the capital lockup.