Journal of Korean Institute of Industrial Engineers (대한산업공학회지)

Korean Institute of Industrial Engineers (대한산업공학회)
권호 표지

Comparative Analysis of Rework Policies in Multistage Production System

다단계 생산시스템에서 재작업정책의 비교분석

  • Shin, Jaeseon (Department of Industrial & Information Engineering, Yonsei University) ;
  • Han, Jooyun (Department of Industrial & Information Engineering, Yonsei University) ;
  • Jeong, Bongju (Department of Industrial & Information Engineering, Yonsei University)
  • 신재선 (연세대학교 정보산업공학과) ;
  • 한주윤 (연세대학교 정보산업공학과) ;
  • 정봉주 (연세대학교 정보산업공학과)
  • Published : 2006.03.31
Download PDF
⟨ Previous Next ⟩

Abstract

As the quality and environmental problems become one of the most concerned issues of company, the rework policy needs to be efficiently designed and implemented to sustain the company's competitiveness. This paper examines three basic rework policies in multi-stage production systems and analyzes them in terms of costs of setup, production, inspection, and inventory. For analyzing the performance of the rework policies, we propose mathematical models which can compute total production cost and determine the optimal production batch size to minimize the total production cost. The rework policies are classified by the number and location of inspection stages. Using the mathematical models, we could analyze the performances of rework policies and suggest the optimal rework policy according to each manufacturing environment. The analyses show that the proposed model can be used to analytically evaluate and choose the rework policies.

Keywords

References

  1. Ben-daya M., Rahim A. (2003), Optimal lot-sizing, quality improvement and inspection errors for multistage production systems Int. J. Prod. Res., 41(1), 65-79 https://doi.org/10.1080/00207540210158816
  2. Chiu, Y. P. (2003), Determining the optimal lot size for the finite production model with random defective rate, the rework process, and backlogging Engineering Optimization, 35(4), 427-437 https://doi.org/10.1080/03052150310001597783
  3. Cho, B. R., Govindaluri, M. S. (2002), Optimal screening limits in multi-stage assemblies, Int. J. Prod. Res., 40(9), 1993-2009 https://doi.org/10.1080/0020754210122266
  4. Flapper, S. D. P, Teunter, R. H. (2004), Logistic planning of rework with deteriorating work-in-process, Int. J. Prod. Economics, 88(1), 51-59 https://doi.org/10.1016/S0925-5273(03)00130-0
  5. Gopalan, M. N., Kannan, S. (1996), Probability of first passage anlysis of a two-stage transfer-line production system with storage and rework Microeletron Reliab., 36(3), 403-407 https://doi.org/10.1016/0026-2714(95)00095-X
  6. Gupta, T., Chakraborty, s. (1984), Looping in a multistage production system Int. J. Prod. Res., 22(2), 299-311 https://doi.org/10.1080/00207548408942455
  7. Hayek, P. A., Salameh, M. K. (2001), Production lot sizing with the reworking of inperfect quality items produced Production Planning and Control, 12(6), 584-590 https://doi.org/10.1080/095372801750397707
  8. Inderfurth, K., Lindner, G., & Rachaniotis, N. P. (2005), Lot sizing in a production system with rework and product deterioration Int. J. Prod. Res., 43(7), 1355-1374 https://doi.org/10.1080/0020754042000298539
  9. Jamal, A. M. M., Sarker, B. R., & Mondal, S. (2004), Optimal manufacturing batch size with rework process at a single-stage production system., Computers & industrial Engineering, 47(1), 77-89 https://doi.org/10.1016/j.cie.2004.03.001
  10. Kang, S. H., Kang, J. Y. (1990), Lot Size Determination in the Kanban System Journal of the Korean Institution of Industrial Engineers, 16(1), 115-122
  11. Kim, C. H., Hong, Y. S., & Kim, S. Y. (1994), An EMQ Model in An Unreliable Machine Journal of the Korean Institution of Industrial Engineers, 20(2), 3-17
  12. Kim, C. H., Hong, Y. S. (1997), An Optimal Production Cycle and Inspection Schedules in A Deteriorating Machine Journal of the Korean Institution of Industrial Engineers, 23(2), 261-273
  13. Kim, C. H. (2005), An EMQ Model with Rework Journal of the Korean Institution of Industrial Engineers, 31(2), 173-179
  14. Lee, H. H., Chandra, M. J., & Deleveaux, V.J. (2003), Optimal batch size and investment and inspection errors for multistage production systems Int. J. Prod. Res., 41(1), 65-79 https://doi.org/10.1080/00207540210158816
  15. Lee, J., Unnikrishnan, S. (1998), Planning quality inspection operations in multistage manufacturing systems with inspection error Int. J. Prod. Res., 36(1), 141-155 https://doi.org/10.1080/002075498193976
  16. Li, J. (2004), Performance analysis of production systems with rework loops IIE Transactions, 36(8), 755-765 https://doi.org/10.1080/07408170490458553
  17. Porteus, E. L. (1986), Optimal lot sizing, process quality improvement and setup cost reduction Operation Research, 34(1), 137-144 https://doi.org/10.1287/opre.34.1.137
  18. Raz, T., Kaspi, M. (1991), Location and sequencing of imperfect inspection operations in serial multi-stage production systems Int. J Prod. Res., 29(8), 1645-1659 https://doi.org/10.1080/00207549108948037
  19. Shiau Y. R. (2002), Inspection resource assignment in a multistage manufacturing system with an inspection error model Int. J. Prod. Res., 40(8), 1787-1806 https://doi.org/10.1080/00207540110119982
  20. Teunter, R. (2004), Lot-sizing for inventory systems with product recovery, Computers & industrial Engineering, 46(3), 431-441 https://doi.org/10.1016/j.cie.2004.01.006
  21. Zargar, A. M. (1995), Effect of Rework Starategies of Cycle Time, Computers & industrial Engineering, 29(1-4), 239-243 https://doi.org/10.1016/0360-8352(95)00078-F