Optimal decision-making for a single-stage manufacturing system with rework options

ABSTRACT

This study investigates a manufacturing system with a single-stage production system that sometimes produces imperfect items. In this system, we assume that the rework process can start after the regular production process (immediate rework) or when the inventory of perfect goods is equal to zero (delayed rework). Also, we assumed non-zero set-up time for rework. Two models are presented for manufacturing systems with re-workable goods. The first model deals with non-zero set-up time for immediate rework and the second model deals with non-zero set-up times for delayed rework. We also investigate special cases associated with these models wherein the set-up times are zero. A general and aggregated model that included those two models is considered. The novelty of this research lies in selecting for a decision-maker the best approach based on system conditions and solutions. This paper provides a framework for rework policies to minimise the total cost of the system, which includes the cost of manufacturing cost, set-up cost for rework and regular production, holding cost for perfect and imperfect items, and the cost of rework. Finally, we solve the aggregated model by using an exact solution algorithm, and the optimal value of production in each period is obtained.

KEYWORDS:

• Lot-sizing
• imperfect production
• rework process
• set-up time
• exact solution algorithm

Disclosure statement

No potential conflict of interest was reported by the authors.

Additional information

Notes on contributors

Amir Hossein Nobil

Amir Hossein Nobil received his MSc from Qazvin Branch, Islamic Azad University, Iran in 2012. Presently, he is pursuing his PhD from the Department of Industrial and Mechanical Engineering at Qazvin Branch, Islamic Azad University, Iran. He is an adjunct lecturer in the Department of Management at Parandak Institute of Higher Education, Iran. His major research interests are inventory management, non-linear optimization, and facility location in supply chain management. He has published papers in International Journal of Production Economics, Expert Systems with Applications, Annals of Operations research, RAIRO, Arabian Journal for Science and Engineering, Scientia Iranica, among others. He is also an editor and a reviewer in several international journals.

Erfan Nobil

Erfan Nobil earned his MSc degrees from and Ruddehn Branch of Islamic Azad University of Iran, respectively. His research focuses on the nonlinear programming problem, coding, and performance assessment of structures.

Bhaba R. Sarker

Bhaba R. Sarker is currently working as a Professor in the Department of Department of Mechanical & Industrial Engineering, Louisiana State University, USA. His research interests includes Production and Manufacturing Systems Engineering, Material Handling and Location Theory, Lean Manufacturing Systems, Supply Chain Management, Renewable Energy, Operations Research, Sequencing and Scheduling. He is serving as an editorial member and reviewer of several international reputed journals. He is the member of many international affiliations. He has successfully completed his Administrative responsibilities. He is author of many research articles/books related to Production and Manufacturing Systems Engineering, Material Handling and Location Theory, Sequencing and Scheduling.