Optimal batch sizing in a multi-stage production system with rework consideration
Optimal batch sizing in a multi-stage production system with rework consideration
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DOI：
10.1016/j.ejor.2006.12.005
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发表时间：
2008-02
期刊：
影响因子：
--
通讯作者：
B. Sarker;A. Jamal;S. Mondal
中科院分区：
文献类型：
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作者：
B. Sarker;A. Jamal;S. Mondal
在生产系统中，返工过程在消除浪费和有效控制制造成本方面起着重要作用。因此，在允许返工的系统中确定最优批大小是一个有价值的目标，可以最大限度地减少在制品和成品的库存成本。本文建立了具有返工过程的多阶段系统的两种不同操作策略下的最优批数量模型。策略1处理同一周期内没有短缺的返工，策略2处理N个周期后完成的返工，导致每个周期出现短缺。在最小化系统成本方面发挥作用的主要组成部分是制造设置、在制品、成品存储、返工处理、等待时间，以及阻止缺陷产生的惩罚成本。该返工加工模型的数学结构属于非线性凸规划问题，给出了该问题的封闭解，并通过数值算例对结果进行了验证，同时对不同重要参数进行了灵敏度分析。结果表明，当在制品持有成本较低时，在缺陷比例较低的情况下，策略2的总成本趋向于小于策略1。当在制品持有成本较低且惩罚成本可以忽略不计时，策略2可能更可取。
In a production system, rework process plays an important role in eliminating waste and effectively controlling the cost of manufacturing. Determining the optimal batch size in a system that allows for rework is, therefore, a worthwhile objective to minimize the inventory cost of work-in-processes and the finished goods. In this paper, models for the optimum batch quantity in a multi-stage system with rework process have been developed for two different operational policies. Policy 1 deals with the rework within the same cycle with no shortage and policy 2 deals with the rework done after N cycles, incurring shortages in each cycle. The major components that play a role in minimizing this cost of the system are manufacturing setups, work-in-processes, storage of finished goods, rework processing, waiting-time, and penalty costs to discourage the generation of defectives. The mathematical structure of this rework processing model falls under a nonlinear convex programming problems for which a closed-form solution has been proposed and results are demonstrated through numerical examples, followed by sensitivity analyses of different important parameters. It is concluded that the total cost in policy 2 tends to be smaller than that in policy 1 at lower proportion of defectives if the in-process carrying cost is low. Policy 2 may be preferred when the work-in-process carrying cost is low and the penalty cost is negligible.