EPQ models for an imperfect manufacturing system considering warm-up production run, shortages during hybrid maintenance period and partial backordering

Unreliable conditions and process deterioration of machines are the major issues in several manufacturing systems. These issues not only affect the production schedules but also affect the product quality significantly. A process warm-up production and amalgamation of the preventive and corrective m...

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Main Authors: S. Ganesan, R. Uthayakumar
Format: Article
Language:English
Published: Elsevier 2020-11-01
Series:Advances in Industrial and Manufacturing Engineering
Subjects:
Online Access:http://www.sciencedirect.com/science/article/pii/S2666912920300052
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spelling doaj-c7a06fd7c7124fa994f18a48516767392021-04-22T13:42:21ZengElsevierAdvances in Industrial and Manufacturing Engineering2666-91292020-11-011100005EPQ models for an imperfect manufacturing system considering warm-up production run, shortages during hybrid maintenance period and partial backorderingS. Ganesan0R. Uthayakumar1Department of Mathematics, Government Polytechnic College, Usilampatti, Tamil Nadu 625537, India; Corresponding author.Department of Mathematics, The Gandhigram Rural Institute (Deemed to be University), Gandhigram, Tamil Nadu 624302, IndiaUnreliable conditions and process deterioration of machines are the major issues in several manufacturing systems. These issues not only affect the production schedules but also affect the product quality significantly. A process warm-up production and amalgamation of the preventive and corrective maintenance are important for the smooth functioning of production activities and improving the product quality. The management needs to handle the product shortages carefully and raise the backorders to upgrade the business economy. To accomplish all these objectives, we develop two production inventory models in this paper by considering a process warm-up production run, hybrid maintenance schedule, anticipated shortages during the maintenance period, and rework of imperfect items. Two different rates are used to distinguish the production of imperfect items in the warm-up and standard production periods. We use fixed and variable lengths to represent the warm-up production period in the two models respectively. The maximum customer waiting time for receiving the backorders is calculated under the consideration of finite replenishment policy and simultaneous regular demand satisfaction. Numerical examples and sensitivity analysis are provided to illustrate the models. The two models are compared based on their annual variable costs. The results suggest that a trade-off between the rework and holding costs of defective items is necessary for better inventory decisions. Determining the optimal value of the length of the warm-up production period is necessary to minimize the annual variable cost.http://www.sciencedirect.com/science/article/pii/S2666912920300052Production inventoryWarm-up productionImperfect manufacturing systemHybrid maintenanceShortagePartial backorder
collection DOAJ
language English
format Article
sources DOAJ
author S. Ganesan
R. Uthayakumar
spellingShingle S. Ganesan
R. Uthayakumar
EPQ models for an imperfect manufacturing system considering warm-up production run, shortages during hybrid maintenance period and partial backordering
Advances in Industrial and Manufacturing Engineering
Production inventory
Warm-up production
Imperfect manufacturing system
Hybrid maintenance
Shortage
Partial backorder
author_facet S. Ganesan
R. Uthayakumar
author_sort S. Ganesan
title EPQ models for an imperfect manufacturing system considering warm-up production run, shortages during hybrid maintenance period and partial backordering
title_short EPQ models for an imperfect manufacturing system considering warm-up production run, shortages during hybrid maintenance period and partial backordering
title_full EPQ models for an imperfect manufacturing system considering warm-up production run, shortages during hybrid maintenance period and partial backordering
title_fullStr EPQ models for an imperfect manufacturing system considering warm-up production run, shortages during hybrid maintenance period and partial backordering
title_full_unstemmed EPQ models for an imperfect manufacturing system considering warm-up production run, shortages during hybrid maintenance period and partial backordering
title_sort epq models for an imperfect manufacturing system considering warm-up production run, shortages during hybrid maintenance period and partial backordering
publisher Elsevier
series Advances in Industrial and Manufacturing Engineering
issn 2666-9129
publishDate 2020-11-01
description Unreliable conditions and process deterioration of machines are the major issues in several manufacturing systems. These issues not only affect the production schedules but also affect the product quality significantly. A process warm-up production and amalgamation of the preventive and corrective maintenance are important for the smooth functioning of production activities and improving the product quality. The management needs to handle the product shortages carefully and raise the backorders to upgrade the business economy. To accomplish all these objectives, we develop two production inventory models in this paper by considering a process warm-up production run, hybrid maintenance schedule, anticipated shortages during the maintenance period, and rework of imperfect items. Two different rates are used to distinguish the production of imperfect items in the warm-up and standard production periods. We use fixed and variable lengths to represent the warm-up production period in the two models respectively. The maximum customer waiting time for receiving the backorders is calculated under the consideration of finite replenishment policy and simultaneous regular demand satisfaction. Numerical examples and sensitivity analysis are provided to illustrate the models. The two models are compared based on their annual variable costs. The results suggest that a trade-off between the rework and holding costs of defective items is necessary for better inventory decisions. Determining the optimal value of the length of the warm-up production period is necessary to minimize the annual variable cost.
topic Production inventory
Warm-up production
Imperfect manufacturing system
Hybrid maintenance
Shortage
Partial backorder
url http://www.sciencedirect.com/science/article/pii/S2666912920300052
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