Integrated Models in Production Planning, Inventory, Quality, and Maintenance

451 Pages·2001·12.991 MB·English

by  M. Ben-Daya, M. A. Rahim (auth.), M. A. Rahim, Mohamed Ben-Daya (eds.)

INTEGRATED MODELS IN
PRODUCTION PLANNING, INVENTORY,
QUALITY, AND MAINTENANCE
INTEGRATED MODELS IN
PRODUCTION PLANNING, INVENTORY,
QUALITY, AND MAINTENANCE
Edited by
M. A. RAHIM
University of New Brunswick
MOHAMED BEN-DAYA
King Fahd University of Petroleum & Minerals
..
,
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Springer Science+Business Media, LLC
Library of Congress Cataloging-in-Publication
Integrated models in production planning, inventory, quality, and maintenance / edited
by M.A. Rahim, Mohamed Ben-Daya.
p. cm.
Includes bibliographical references and index.
ISBN 978-1-4613-5652-3 ISBN 978-1-4615-1635-4 (eBook)
DOI 10.1007/978-1-4615-1635-4
1. Production planning. 2. Inventory control. 3. Production scheduling. 1. Rahim, M.
A. II. Ben-Daya, M. (Mohamed)
TS176 .155142001
658.5--dc21
2001029405
Copyright © 2001 Springer Science+Business Media New York
Originally published by Kluwer Academic Publishers in 2001
Softcover reprint of the hardcover 1s t edition 2001
AlI rights reserved. No part of this publication may be reproduced, stored in a
retrieval system or transmitted in any form or by any means, mechanical, photo
copying, recording, or otherwise, without the prior written permission of the
publisher, Springer Science+Business Media, LLC.
Printed on acid-free paper.
Contents
List of Figures xi
List of Tables xiii
Preface xvii
Acknowlegments xxi
Contributing Authors xxiii
Part I INTRODUCTION
1
Integrated Production, Quality & Maintenance Mod- 3
els: An Overview
M. Ben-Daya and M.A. Rahim
1. Introduction 3
2. Preliminaries 4
3. Production and Quality 6
4. Production and Maintenance 9
5. Maintenance and Quality 13
6. Joint Models for Maintenance, Production and Quality 15
7. Integrated Models for Multi-Stage Systems 15
8. Other Integrated Models 16
9. Conclusion and Directions for Future Research 18
Part II PRODUCTION AND MAINTENANACE
2
Computation Algorithms of Cost-Effective EMQ Poli- 31
des with PM
H. Okamura, T. Dohi, and S. Osaki
1. Introduction 31
VI INTEGRATED MODELS IN PRODUCTION PLANNING
2. Model description 35
3. Poisson Process Demand 38
4. Diffusion Approximation 43
5. Phase Approximation 49
6. Numerical Illustrations 55
7. Conclusion 60
3
Optimal Control Policy for a General EM Q Model 67
with Random Machine Failure
V. Makis and X. Jiang
1. Introduction 67
2. Problem Formulation 69
3. Optimal Inspection Schedule for One Production Cycle 71
4. Optimal Lot Sizing and Replacement Policy 73
5. Computational Algorithm and Numerical Example 76
4
A Production/Inventory Policy for an Unreliable Machine 79
Hyo-Seong Lee and Mandyam M. Srinivasan
1. Introduction 80
2. The Model 83
3. Properties of the cost function 86
4. Numerical examples 90
5. Conclusions 92
5
Integrating Maintenance, Lot Sizing and Production 95
Planning for a Single Machine Multi-Product System
Suresh K. Goyal and Yasemin Kahyaoglu
1. Introduction 95
2. Assumptions 96
3. Notation 96
4. Numerical Example 100
6
Optimal Models of Preventive Maintenance and Re- 105
placement Policies
Eli Shemesh, Abraham Mehrez and Gad Rabinowitz
1. Introduction 105
2. The Model Parameters and Notation 109
3. General Problem Solution of the Optimal Maintenance Strat-
egy 111
4. Stochastic Machine Replace- ment in Finite Horizon 115
5. Numerical Examples 117
6. Conclusions and Applications for Future Research 122
Contents Vll
Part III PRODUCTION/INVENTORY AND QUALITY
7
An Integrated Economic Model for Inventory and 129
Statistical Process Control
Enrique Del Castillo and Isabel T. Salcedo
1. Introduction 130
2. The Semi-Markov model 131
3. Economic Optimization Model 136
8
A Generalized Integrated Economic Model for Inven- 145
tory and Quality Control Problems
Hiroshi Ohta, Aritoshi Kimura and M. Abdur Rahim
1. Introduction 146
2. Notations and Assumptions 149
3. General Model 151
4. Examples 155
5. Concluding Remarks 158
9
Optimal Inventory Ordering Policies for Quality-Dependent 161
Markets
M. Hariga and M. N. Azaiez
1. Introduction 161
2. Model Formulation 164
3. Selecting among alternative arrangements 169
4. Integrated inventory-pricing model 172
5. Conclusion 179
10
Manufacturing System Modeling and Control 185
E. K. Boukas and Z. K. Liu
1. Introduction 185
2. Basic Production Model 187
3. Controlled Piecewise-Deterministic Processes and Numerical
Technique 190
4. Manufacturing System with Deteriorating Terms 195
5. Production System with Quality Control 202
6. Production and Marketing Control 216
7. Concluding Remarks 225
11
A Single Period Inventory Model to Account for De- 231
mand Surprises
Dogman Serel and Herbert Moskowitz
1. Introduction 231
2. Model Assumptions 233
3. The Optimal Order Quantity 234
4. Numerical Example 237
5. Sensitivity Analysis 238
6. Summary and Extensions 238
viii INTEGRATED MODELS IN PRODUCTION PLANNING
Part IV QUALITY AND MAINTENANCE
12
Improving and Maintaining Process Profitability 245
Elart von Collani and Gudrun Kiesmiiller
1. The Production Process 246
2. The Control Model 254
3. Process Monitoring 257
4. Process Profitability 259
5. Monitoring and Maintenance Policy 261
6. Normally Distributed Quality Characteristic 262
7. Numerical Example 272
8. Conclusions 273
13
A Simple Model for the Effect of Manufacturing Pro- 277
cess Quality on Product Reliability
Michael Tortorella
1. Introduction 277
2. How Does Manufacturing Process Quality Affect Product Re-
liability? 279
3. An Illustration 282
4. Conclusions and Related Questions 285
Part V WARRANTY, MANUFACTURING AND QUALITY
14
Warranty and Manufacturing 289
K.F. Lyons and D.N.P. Murthy
1. Introduction 289
2. Product Warranty: An Overview 291
3. Warranty as an Integrative Element in Manufacturing 292
4. Warranty Management System 294
5. Models and Data Management 305
6. Conclusion 319
15
Warranty and Quality 325
D.N.P. Murthy and I. Djamaludin
1. Introduction 325
2. Product Warranty 327
3. Quality 332
4. Warranty and Quality: Review of Models 341
5. Conclusion and Topics for Future Research 355
Part VI QUALITY
16
SPC-based Diagnosis of Processes with Multiple Con- 363
current Dysfunctional Steps
John R. English, Mohammed Alsein, and Michael H. Cole
Contents IX
1. Introduction and motivation 364
2. Related Literature 364
3. SPC approach to process diagnosis 365
4. Results of comparisons between MDS and SDS 368
5. Conclusions 380
17
Stepwise-Programmed Regulation of Manufacturing 383
Quality
John J. Liu
1. Introduction 383
2. Dispersal Quality Regulation 385
3. Singular Characteristics of DQR 389
4. Singular Dispersal Solutions of DQR 393
5. Optimal Quality Regulation Strategy 395
6. Conclusions 396
18
Simultaneous Monitoring Of Mean And Variance through 399
Optimally Designed SPRT Charts
Felipe Pachano-Azuaje and Tapas K. Das
1. Introduction 400
2. Joint SPRT Control Charts for Mean and Variance 405
3. Development of Economic Models 410
4. Numerical Results 423
5. Conclusions 436
Index 441
List of Figures
2.1 Configuration of the EMQ model with PM. 37
2.2 Configuration of the EMQ model with PM using the
virtual stock level. 37
4.1 The Production/Inventory System Where N = 2. 85
4.2 Au and Av for an increasing function, h(t), with v > u. 88
5.1 Production and maintenance schedule for Alterna-
tive 1 101
5.2 Production and maintenance schedule for Alterna-
tive 2 103
6.1 Optimal machine replacement sequences under de-
terministic cases of t3. 119
6.2 Probability of machine's use over time, under Geo-
metric PDF with p=O.07 120
6.3 Deterministic NPV for TL1 and TL2 versus ma-
chine life-cycle. 121
6.4 Deterministic NPV versus the introduction time of
a TL3 machine. 121
7.1 Transitions between two consecutive samples. 133
7.2 A typical inventory graph, showing the average in-
ventory slope. 135
8.1 Quality and inventory control cycle 156
10.1 maintenance rates w1(x, 2), w~(x, 2) . 203
10.2 Value function v(x, i) versus x. 214
10.3 Production rate u(x, i) versus x. 215
10.4 maintenance rates w~(x, 2), w~(x, 2) . 215
14.1 Interactions between warranty related issues (from
Murthy and Blischke (1994». 293
xii INTEGRATED MODELS IN PRODUCTION PLANNING
14.2 Warranty Management System Modules 295
14.3 Characterisation of the Total Warranty Cost 296
14.4 D&E Module 297
14.5 Flow of Activities in the D&E Module 297
14.6 Production Module 299
14.7 Flow of Activities in the Production Module 300
14.8 Marketing Module 302
14.9 Flow of Activities in the Marketing Module 303
14.10 Post Sale Servicing Module 305
14.11 Flow of Activities in the Post-Sale Servicing Module 306
14.12 Failure Model Hierarchy 308
14.13 Database Management System (adapted from Beynon-
Davies and Hutchings (1993)) 318
16.1 M Step Process characterized by N Process Variables. 367
16.2 Interaction plot of number of process variables vs. p. 372
16.3 Interaction plot of number of process variables vs. p value. 374
16.4 Interaction plot of Steps vs. Shifts. 375
16.5 Interaction plot of Steps vs. Number of Process
variables (Var). 375
16.6 Interaction plot of Var vs. value of p. 378
16.7 Interaction plot of Shifts vs. value of p. 379
16.8 Interaction plot of Steps vs. value of p. 379
16.9 Interaction plot of Steps vs. Shift. 380
17.1 Stepwise-programmed regulation 387
17.2 Dispersal singular paths and characteristics 392
18.1 A sequential probability ratio test chart for the mean
(as in (18.11)). 408
18.2 A sequential probability ratio test chart for the variance. 411
18.3 Two sample cases of joint SPRT from (18.64) and (18.65).421
18.4 Decision Limits in Mean Charts for Operational and
Reference Designs. 425