Volume 56, Number 2, March-April 2022
|Page(s)||871 - 889|
|Published online||14 April 2022|
Controlling defective items in a complex multi-phase manufacturing system
Department of Industrial Engineering, Yonsei University, 50 Yonsei-ro, Sinchon-dong, Seadaemun-gu, Seoul 03722, South Korea
2 Center for Transdisciplinary Research (CFTR), Saveetha Dental College, Saveetha Institute of Medical and Technical Sciences, Saveetha University 162, Poonamallee High Road, Velappanchavadi, Chennai 600077, Tamil Nadu, India
3 Information Technology Research Center, Chung-Ang University, Seoul 06974, South Korea
* Corresponding author: email@example.com
Accepted: 5 February 2022
In manufacturing systems, defective items are produced for machine drift and error. Usually, an imperfect production rate is random, and if the items are not reworked, these are considered trash and harm the environment. The proposed model aims to reduce waste by reworking defective products and maximizing profit. For profit maximization or overall cost minimization of the manufacturing system, setup cost has significant. A discrete investment for each phase is introduced with an inequality investment constraint for reducing the setup cost. Selling price-dependent demand is trained for more generalized applications for various industries. The proposed model is a multi-phase manufacturing system with optimum batch size, selling price, and investment with an irregular, imperfect production rate. Defects are detected at the first inspection, and the reworked items are checked if the reworked items are all non-defective in the second inspection. The model conducts a two-stage inspection. One is for detecting defective items, and another is for checking if all items are not defective after reworking. The model is solved with the Karush–Kuhn–Tucker (KKT) method, and the global maximum profit is obtained. The model shows that all investments should be assigned to maximize the profit and the optimal solution. Reducing setup cost with the investment is better than a constant setup cost.
Mathematics Subject Classification: 90B05 / 90B06
Key words: Manufacturing systems / remanufacturing / makespan / investment appraisal / inspection
© The authors. Published by EDP Sciences, ROADEF, SMAI 2022
This is an Open Access article distributed under the terms of the Creative Commons Attribution License (https://creativecommons.org/licenses/by/4.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
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