DOI: 10.5937/jaes0-29717
This is an open access article distributed under the CC BY 4.0
Volume 19 article 852 pages: 774-786
Transnational manufacturing firms operate in highly competitive marketplaces. This means that they are continuously seeking ways to reduce order response and fabrication cycle times, maintain the desired product quality, manage unanticipated machine failures, and provide timely delivery to effectively minimize overall operating cost and maintain a competitive advantage over their intra-supply chains. To assist firms in achieving these operational goals, we examine a buyer-vendor coordinated system with an expedited fabrication rate, unreliable machines, scrap, and rework, with the objective of minimizing the overall operating costs. An imperfect manufacturing process is assumed, which arbitrarily produces repairable and scrap items, with the latter being reworked in each fabrication cycle. Additionally, the process is subject to a Poisson-distributed machine breakdown. The corrective action is undertaken immediately when the machine fails, and the production of unfinished/interrupted lot resumes when the process is restored. The expedited fabrication rate option is used at an extra cost to reduce the cycle length. We built a fabrication-shipment model to characterize the problem’s features explicitly. Mathematical and optimization approaches assist us in determining the optimal fabrication runtime policy. A numerical example illustrates the capability/applicability of our outcomes. Furthermore, it exposes a diverse set of information relating to the collective/individual effect of differences in the expedited rates, mean-time-to-breakdown, frequency of shipment, and rework/disposal rates of defective items on the optimal policy, utilization, total operating cost, and various cost contributors. This information can contribute to facilitating better decision-making.
The authors thank the Ministry of Science and Technology
of Taiwan for sponsoring this study (Funding number:
MOST 108-2221-E-324-009).
1. Gershwin, S.B. (1987). Representation and analysis of transfer lines with machines that have different processing rates. Annals of Operations Research, 9(1), 511–530. DOI: 10.1007/BF02054752
2. Makino, H., Tominaga, M. (1995). Estimation of production rate in flexible assembly systems. CIRP Annals of Manufacturing Technology, 44(1), 7–10. DOI: 10.1016/S0007-8506(07)62263-X
3. Freiheit, T., Shpitalni, M., Hu, S.J., Koren, Y. (2004). Productivity of synchronized serial production lines with flexible reserve capacity. International Journal of Production Research, 42(10), 2009-2027. DOI: 10.1081/00207540310001647596
4. Singh, S.R., Sharma, S. (2013). An integrated model with variable production and demand rate under inflation. Procedia Technology, 10, 381–391. DOI: 10.1016/j.protcy.2013.12.374
5. Chiu, S.W., Wu, C-S., Tseng, C-T. (2019). Incorporating an expedited rate, rework, and a multi-shipment policy into a multi-item stock refilling system. Operations Research Perspectives, 6, 1-12, art. no. 100115. DOI: 10.1016/j.orp.2019.100115
6. Chiu, Y.-S.P., Chen, H.-Y., Chiu, S.W., Chiu, V. (2018). Optimization of an economic production quantity-based system with random scrap and adjustable production rate. Journal of Applied Engineering Science, vol. 16, br. 1, str. 11-18. DOI: 10.5937/jaes16-15458
7. Ameen, W., AlKahtani, M., Mohammed, M.K., Abdulhameed, O., El-Tamimi, A.M. (2018). Investigation of the effect of buffer storage capacity and repair rate on production line efficiency. Journal of King Saud University - Engineering Sciences, 30(3), 243-249. DOI: 10.1016/j.jksues.2018.03.001
8. Chiu, S.W., Huang, Y-J., Chiu, Y-S.P., Chiu, T. (2019). Satisfying multiproduct demand with a FPR-based inventory system featuring expedited rate and scraps. International Journal of Industrial Engineering Computations, 10(3), 443-452. DOI: 10.5267/j.ijiec.2018.11.001
9. Demić, M., Rakićević, B., Jovanović, M., Miličić, B. (2020). Research into truck transmission torsion vibrations under longitudinal acceleration. Journal of Applied Engineering Science, vol. 18, br. 2, str. 243-250. DOI: 10.5937/jaes18-23164
10. Moinzadeh, K., Lee, H.L. (1987). A continuous˗review inventory model with constant resupply time and defective items. Naval Research Logistics, 34(4), 457-467. DOI: 10.1002/1520-6750(198708)34:43.0.CO;2-O
11. Hong, Y., Glassey, C.R., Seong, D. (1992). The analysis of a production line with unreliable machines and random processing times. IIE Transactions, 24(1), 77-83. DOI: 10.1080/07408179208964201
12. Geren, N., Lo, E.K. (1998). Equipment selection, integration and interfacing of a robotic PCBA component rework cell. Computer Integrated Manufacturing Systems, 11(1-2), 77-89. DOI: 10.1016/S0951-5240(98)00014-7
13. Kyriakidis, E., Dimitrakos, T. (2006). Optimal preventive maintenance of a production system with an intermediate buffer. European Journal of Operational Research, 168, 86–99. DOI: 10.1016/j.ejor.2004.01.052
14. Widyadana, G.A., Wee, H.M. (2012). An economic production quantity model for deteriorating items with multiple production setups and rework. International Journal Production Economics, 138(1), 62-67. DOI: 10.1016/j.ijpe.2012.02.025
15. Nasr, W.W., Salameh, M., Moussawi-Haidar, L. (2017). Economic production quantity with maintenance interruptions under random and correlated yields. International Journal of Production Research, 55(16), 4544-4556. DOI: 10.1080/00207543.2016.1265684
16. Zhao, X., Qian, C., Nakamura, S., Nakagawa, T. (2018). A summary of replacement policies with number of failures. International Journal of Mathematical, Engineering and Management Sciences, 3(2), 136-150. DOI: 10.33889/IJMEMS.2018.3.2-011
17. de Vasconcelos, V., Soares, W.A., da Costa, A.C.L., Raso, A.L. (2019). Use of reliability block diagram and fault tree techniques in reliability analysis of emergency diesel generators of nuclear power plants. International Journal of Mathematical, Engineering and Management Sciences, 4(4), 814-823. DOI: 10.33889/IJMEMS.2019.4.4-064
18. Zammori, F., Bertolini, M., Mezzogori, D. (2020). A constructive algorithm to maximize the useful life of a mechanical system subjected to ageing, with non-resuppliable spares parts. International Journal of Industrial Engineering Computations, 11(1), 17-34. DOI: 10.5267/j.ijiec.2019.7.001
19. Gabitov, I., Insafuddinov, S., Ivanov, Y., Yunusbaev, N., Abdrazakov, F., Farhutdinov, T. (2020). Examination of the system of continuous diagnosis and forecasting of mechanical condition of tractors and other farm machinery. Journal of Applied Engineering Science, vol. 18, br. 1, str. 70-80. DOI: 10.5937/jaes18-22568
20. Aderohunmu, R., Mobolurin, A., Bryson, N. (1995). Joint vendor-buyer policy in JIT manufacturing. Journal of the Operational Research Society, 46(3), 375-385. DOI: 10.2307/2584331
21. Thomas D.J., Hackman S.T. (2003). A committed delivery strategy with fixed frequency and quantity. European Journal of Operational Research, 148(2), 363-373. DOI: 10.1016/S0377-2217(02)00398-3
22. Shaw, D.K., Mishra, A., Khan, D.A. (2012). An integrated inventory model for single vendor multi customer scenario with multiple shipments in a supply chain. International Journal of Mathematical, Engineering and Management Sciences, 7(2), 140-146. DOI: 10.1080/17509653.2012.10671217
23. Urrea, C., Pascal, J. (2018). Algorithms for the generation of autonomous routes. Journal of Applied Research and Technology, 16(5), 373-383. DOI: 10.22201/icat.16656423.2018.16.5.740
24. Batukhtin, A., Batukhtina, I., Bass, M., Batukhtin, S., Kobylkin, M., Baranovskaya, M., Baranovskaya, A. (2019). Development and experimental verification of the mathematical model of thermal inertia for a branched heat supply system. Journal of Applied Engineering Science, vol. 17, br. 3, str. 413-424. DOI: 10.5937/jaes17-22408
25. López-Ruíz, S., Carmona-Benítez, R.B. (2019). The design of a liquefied natural gas (LNG) distribution network of a company operating in Mexico. Journal of Applied Research and Technology, 17(4), 213-249. DOI: 10.22201/icat.16656423.2019.17.4.818
26. Chiu, S.W., Lin, J-N., Wang, Y., Lin, H-D. (2020). Mathematical modeling for multiproduct EPQ problem featuring delayed differentiation, expedited rate, and scrap. International Journal for Engineering Modelling, 33(3-4), 75-95. DOI:10.31534/engmod.2020.3-4.ri.05v
27. Singamsetty, P., Thenepalle, J.K. (2021). Designing optimal route for the distribution chain of a rural LPG delivery system. International Journal of Industrial Engineering Computations, 12(2), 221-234. DOI: 10.5267/j.ijiec.2020.11.001