Optimal initial production control period based on a quality growth model

The initial production phase of new products or the initial installation phase of new manufacturing facilities is often unstable because of inexperienced workers and many defective products. An initial production process control, in which the defects in design, production technologies and products are fully fixed and removed, is switched to a normal process control whenever it is ready for actual mass production. This paper discusses a method of deciding the optimal initial production control period based on a quality growth model. It is determined by the number of products with the minimum expected total quality control cost. Finally a penalty cost due to unattainable loss to the quality goal is introduced in the quality control cost: the realized stabilization level of the initial production process control is lower than the original quality objective. Numerical illustrations of the optimal policy are also presented.