Manufacturing runtime problem with an expedited fabrication rate, random failures, and scrap

Chiu, Singa Wang; Huang, Yijing; Chou, Chung-Li; Chiu, Yuan‐Shyi Peter

doi:10.5267/j.ijiec.2019.6.006

Cited by 3 publications

(2 citation statements)

References 29 publications

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“…The researchers first discussed/ evaluated KPIs of a real case of outsourcing information technology services of a telecommunication vendor and then extended to two different settings to demonstrate their evaluation procedures at both client and vendor sides. Recent works [20][21][22][23] also explored the impact of different aspects of adjusted fabrication rate and subcontracting on planning, operations, and management of diverse manufacturing and supply-chain systems. Since few past works have developed a precise model to derive the optimal replenishing policy and explicitly disclose collective/individual impact of postponement, rework, and dual uptime-reduced strategies on the problem's operating cycle policy and crucial performance indices, we aim to serve this purpose and help manufacturers have better control over their operations and facilitate their effective/efficient decision-making.…”

Section: Survey Of Previous Researchmentioning

confidence: 99%

Optimizing a multiproduct manufacturing system with delayed differentiation, outsourcing, expedited rate, and rework strategies

Chiu¹,

Ke²,

Chiu³

et al. 2021

J Appl Eng Science

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This study examines the effect of delayed differentiation, outsourcing, expedited fabrication rate, and rework strategies on optimal cycle-time decisions for a multi-item manufacturing system. Today’s manufacturing firms must simultaneously deal with externally increasing client multi-item requirements with rapid lead-time and high-quality products and internally on a limited capacity. This study is aimed at assisting manufacturers in meeting client needs in conditions of restricted-capacity and minimum total operating expenses, and adopts a delayed differentiation two-stage multiproduct manufacturing scheme to manage the end products’ commonality. The first stage produces all required common components, and the second stage fabricates individual finished goods. In both stages, we adopt the reworking of the inevitable nonconforming items produced to assure product quality. Furthermore, we implemented partial outsourcing of common parts’ batch and expedited the manufacturing rate of finished products to effectively reduce the uptimes in both stages. We explicitly developed a model to describe the characteristics of the problem. Mathematical analyses with optimization proved the cost function’s convexity and determined the cost-minimization rotation cycle policy. Finally, we numerically validated our model’s and results’ applicability and capability with a simulated example. Apart from creating a useful decision model, this study makes another important contribution to the existing literature in that its revelation of collective/individual effect of the manufacturing-relevant methods on the problem’s best-operating cycle policy and crucial performance indices helps manufacturers have better control over their operations and make effective and efficient managerial decisions.

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Section: Survey Of Previous Researchmentioning

confidence: 99%

Optimizing a multiproduct manufacturing system with delayed differentiation, outsourcing, expedited rate, and rework strategies

Chiu¹,

Ke²,

Chiu³

et al. 2021

J Appl Eng Science

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show abstract

“…Machines constitute one of the most important resources in manufacturing. Machine failures are inevitable due to unexpected variations in manufacturing processes (Chiu et al, 2020) and, along with faulty production, affect the efficiency of a manufacturing process (Borucka and Grzelak, 2019). In addition, machine failures can cause large production losses by creating many negative consequences (Xia et al, 2013).…”

Section: Introductionmentioning

confidence: 99%

Machine Failure Analysis Using Multinomial Logistic Regression

Koçak¹

2022

isarder

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Purpose: The main purpose of this study is to carry out a failure analysis of a filling machine by applying multinomial logistic regression.Design/methodology/approach:For this purpose,data related to failure mode, product, scrap rate, and shift parameters were collected from the machine and analysis was conducted by establishing two multinomial logistic regression models.Findings: Statistical results suggest that a hydraulic failure must be expected while filling the mix product. Besides, it is highly probable that a final folder failure will occur while filling the cherry product. Paper failure stands out while filling the apple product compared to other products. In addition, it is likely that a final folder failure will occur while filling this product. Photocell failure is common while filling the peach product. Results of the study show that the odd for low-level scrap is high when there is any failure in the machine.Discussion: A more effective analysis can be performed by collecting parameters that may affect the position of machinery such as vibration, humidity, temperature and pressure through the sensors to be installedon various units of the filling machine and adding them into the models developed under the study.

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Manufacturing runtime problem with an expedited fabrication rate, random failures, and scrap

Chiu¹,

Huang²,

Chou³

et al. 2020

10.5267/j.ijiec

Self Cite

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When operating in highly competitive business environments, contemporary manufacturing firms must persistently find ways to fulfill timely orders with quality ensured merchandise, manage the unanticipated fabrication disruptions, and minimize total operating expenses. To address the aforementioned concerns, this study explores the optimal runtime decision for a manufacturing system featuring an expedited fabrication rate, random equipment failures, and scrap. Specifically, the proposed study considers an expedited rate that is linked to higher setup and unit costs. The fabrication process is subject to random failure and scrap rates. The failure instance follows a Poisson distribution, is repaired right away, and the fabrication of interrupted batch resumes when the equipment is restored. The defective goods are identified and scrapped. Mathematical modeling and optimization method are used to find the total system cost and the optimal runtime of the problem. The applicability and sensitivity analyses of research outcome are illustrated through a numerical example. Diverse critical information regarding the individual/joint impacts of variations in stochastic time-to-failure, expedited rate, and random scrap on the optimal runtime decision, total system expenses, different cost components, and machine utilization, can now be revealed to assist in in-depth problem analyses and decision makings.

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Manufacturing runtime problem with an expedited fabrication rate, random failures, and scrap

Cited by 3 publications

References 29 publications

Optimizing a multiproduct manufacturing system with delayed differentiation, outsourcing, expedited rate, and rework strategies

Optimizing a multiproduct manufacturing system with delayed differentiation, outsourcing, expedited rate, and rework strategies

Machine Failure Analysis Using Multinomial Logistic Regression

Manufacturing runtime problem with an expedited fabrication rate, random failures, and scrap

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