Integrated product specifications and productivity decision making in unreliable manufacturing systems

Integrated product specifications and productivity decision making in unreliable manufacturing systems

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Article ID: iaor20108299
Volume: 129
Issue: 1
Start Page Number: 32
End Page Number: 42
Publication Date: Jan 2011
Journal: International Journal of Production Economics
Authors: , , , ,
Keywords: decision: rules, simulation: applications
Abstract:

This paper considers joint production control and product specifications decision making in a failure prone manufacturing system. This is with the knowledge that tight process specifications, while leading to a product of more reliable quality and higher market value, are at the same time associated with higher levels of non-conforming parts, a higher rate of parts rejection and thus a lowering of overall plant productivity. The decision making is further complicated by the lack of reliability of the production process, which imposes that an adequate, also to be designed, level of inventory of finished parts be maintained. The overall optimal decision policy is defined here as one that maximizes the long term average per unit time profit of a combined measure of quality and quantity dependent sales revenue, minus inventory and backlog costs, in the presence of random plant failures and random repair durations. Policy optimization is achieved via a revisited model of the Bielecki‐Kumar theory for Markovian machines and a simulation and experimental design based methodology for the more general cases.

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