DOI QR코드

DOI QR Code

A Study of Inventory Models for Imperfect Manufacturing Setup Considering Work-in-Process Inventory

재공품 재고를 고려한 제조 시스템에서의 재고 관리 모델 연구

  • Ullah, Misbah (Department of Industrial and Management Engineering, ERICA Campus, Hanyang University) ;
  • Kang, Chang W. (Department of Industrial and Management Engineering, ERICA Campus, Hanyang University) ;
  • Qureshi, Shehereyar Mohsin (Department of Industrial and Management Engineering, ERICA Campus, Hanyang University)
  • Received : 2014.11.10
  • Accepted : 2014.12.06
  • Published : 2014.12.31

Abstract

Optimum lot size calculation for real world manufacturing environment has been focused since last few decades. Several extensions have been made to the basic economic order and production order quantity models to realize the possible practical situations in industry. However, focus on work-in-process inventory has been ignored relatively. This paper provides a comprehensive review of the models developed for group technology based manufacturing environment focusing on work-in-process inventory. Models have been extended from a perfect manufacturing conditions to an imperfect manufacturing situation considering rework, rejection and inspection. Optimum lot size has been evaluated using a simple algebraic optimization approach. Significant parameters are highlighted using sensitivity analysis for the developed models. Numerical example is used to illustrate the utilization of such models in day-to-day production setups and the impact of significant factors' variation on total cost and optimum lot size.

Keywords

References

  1. Harris, F.W., How many parts to make at once. Operations Research, 1990, 38(6): p 947-950. https://doi.org/10.1287/opre.38.6.947
  2. Gupta, T. and Chakraborty, S., Looping in a multistage production system. The International Journal of Production Research, 1984, Vol. 22, No. 2, p 299-311. https://doi.org/10.1080/00207548408942455
  3. Rosenblatt, M.J. and Lee, H.L., Economic production cycles with imperfect production processes. IIE transactions, 1986, Vol. 18, No. 1, p 48-55. https://doi.org/10.1080/07408178608975329
  4. Cheng, T., An economic order quantity model with demand- dependent unit production cost and imperfect production processes. IIE transactions, 1991, Vol. 23, No. 1, p 23-28. https://doi.org/10.1080/07408179108963838
  5. Ben-Daya, M. and Hariga, M., Economic lot scheduling problem with imperfect production processes. Journal of the Operational Research Society, 2000, Vol. 51, No. 7, p 875-881. https://doi.org/10.1057/palgrave.jors.2600974
  6. Salameh, M. and Jaber, M., Economic production quantity model for items with imperfect quality. International Journal of Production Economics, 2000, Vol. 64, No. 1, p 59-64. https://doi.org/10.1016/S0925-5273(99)00044-4
  7. Goyal, S.K. and Cardenas-Barron, L.E., Note on: economic production quantity model for items with imperfect quality -a practical approach. International Journal of Production Economics, 2002, Vol. 77, No. 1, p 85-87. https://doi.org/10.1016/S0925-5273(01)00203-1
  8. Biswas, P. and Sarker, B.R., Optimal batch quantity models for a lean production system with in-cycle rework and scrap. International Journal of Production Research, 2008, Vol. 46, No. 23, p 6585-6610. https://doi.org/10.1080/00207540802230330
  9. Jamal, A., Sarker, B.R., and Mondal, S., Optimal manufacturing batch size with rework process at a singlestage production system. Computers and Industrial Engineering, 2004, Vol. 47, No. 1, p 77-89. https://doi.org/10.1016/j.cie.2004.03.001
  10. Chiu, S.W., Ting, C.-K., and Chiu, Y.-S.P., Optimal production lot sizing with rework, scrap rate, and service level constraint. Mathematical and Computer Modelling, 2007, Vol. 46, No. 3-4, p 535-549. https://doi.org/10.1016/j.mcm.2006.11.031
  11. Chan, W., Ibrahim, R., and Lochert, P., A new EPQ model : integrating lower pricing, rework and reject situations. Production Planning and Control, 2003, Vol. 14, No. 7, p 588-595. https://doi.org/10.1080/09537280310001626179
  12. Pal, B., Sana, S.S., and Chaudhuri, K., Maximising profits for an EPQ model with unreliable machine and rework of random defective items. International Journal of Systems Science, 2013, Vol. 44, No. 3, p 582-594. https://doi.org/10.1080/00207721.2011.617896
  13. Ojha, D., Sarker, B., and Biswas, P., An optimal batch size for an imperfect production system with quality assurance and rework. International Journal of Production Research, 2007, Vol. 45, No. 14, p 3191-3214. https://doi.org/10.1080/00207540600711853
  14. Chiu, S.W., Wang, S.-L., and Chiu, Y.-S.P., Determining the optimal run time for EPQ model with scrap, rework, and stochastic breakdowns. European Journal of Operational Research, 2007, Vol. 180, No. 2, p 664- 676. https://doi.org/10.1016/j.ejor.2006.05.005
  15. Sarkar, B., An EOQ model with delay in payments and stock dependent demand in the presence of imperfect production. Applied Mathematics and Computation, 2012, Vol. 218, No. 17, p 8295-8308. https://doi.org/10.1016/j.amc.2012.01.053
  16. Sarkar et al., An economic production quantity model with random defective rate, rework process and backorders for a single stage production system. Journal of Manufacturing Systems, 2014, Vol. 33, No. 3, p 423- 435. https://doi.org/10.1016/j.jmsy.2014.02.001
  17. Sarkar, B., Mandal, P., and Sarkar, S., An EMQ model with price and time dependent demand under the effect of reliability and inflation. Applied Mathematics and Computation, 2014, Vol. 231, p 414-421. https://doi.org/10.1016/j.amc.2014.01.004
  18. Wee, H.M. and Widyadana, G.A., Economic production quantity models for deteriorating items with rework and stochastic preventive maintenance time. International Journal of Production Research, 2011, Vol. 50, No. 11, p 2940-2952.
  19. Sana, S.S., A production-inventory model in an imperfect production process. European Journal of Operational Research, 2010, Vol. 200, No. 2, p 451-464. https://doi.org/10.1016/j.ejor.2009.01.041
  20. Sana, S.S., An economic production lot size model in an imperfect production system. European Journal of Operational Research, 2010, Vol. 201, No. 1, p 158-170. https://doi.org/10.1016/j.ejor.2009.02.027
  21. Sana, S.S. and Chaudhuri, K., An EMQ model in an imperfect production process. International Journal of Systems Science, 2010, Vol. 41, No. 6, p 635-646. https://doi.org/10.1080/00207720903144495
  22. Khan, M. et al., A review of the extensions of a modified EOQ model for imperfect quality items. International Journal of Production Economics, 2011, Vol. 132, No. 1, p 1-12. https://doi.org/10.1016/j.ijpe.2011.03.009
  23. Bough Er, T.O., Lot sizing in group technology production systems. International Journal of Production Research, 1984, Vol. 22, No. 1, p 85-93. https://doi.org/10.1080/00207548408942432
  24. Cardenas-Barron, L.E., The derivation of EOQ/EPQ inventory models with two backorders costs using analytic geometry and algebra. Applied Mathematical Modelling, 2011, Vol. 35, No. 5, p 2394-2407. https://doi.org/10.1016/j.apm.2010.11.053
  25. Barzoki, M.R., Jahanbazi, M., and Bijari, M., Effects of imperfect products on lot sizing with work in process inventory. Applied Mathematics and Computation, 2011, Vol. 217, No. 21, p 8328-8336. https://doi.org/10.1016/j.amc.2011.03.023
  26. Ullah, M. and Kang, C.W., Effect of rework, rejects and inspection on lot size with work-in-process inventory. International Journal of Production Research, 2014, Vol. 52, No. 8, p 2448-2460. https://doi.org/10.1080/00207543.2013.873554
  27. Kim, H., Maximizing expected profit via multiple truck operation under imperfect truck quality. Journal of the Society of Korea Industrial and System Engineering, 2012, Vol. 35, p 45-51.
  28. Han, Y. and Kim, H., An optimal solution algorithm of the single product inventory with target in-stock ratio constant. Journal of the Society of Korea Industrial and Systems Engineering, 2012, Vol. 35, p 204-209.

Cited by

  1. Effect of Time-Varying Factors on Optimal Combination of Quality Inspectors for Offline Inspection Station vol.7, pp.1, 2014, https://doi.org/10.3390/math7010051