The effects of the warranty cost on the imperfect EMQ model with general discrete shift distribution

In this paper, we investigate the effect of the warranty cost on optimization of the economic manufacturing quality (EMQ). This is done for a deteriorating process where the production process shifts from the in-control state to the out-of-control state following a general discrete probability distribution. Once the production process goes out of control, the production process produces some defective items. The defective item cost includes reworking and warranty costs. Thus, in order to economically operate a production-inventory system with products sold under warranty, the tradeoffs among the production setup, inventory, and defective item cost, including the reworked cost before sale and the warranty cost after sale, needed to be analysed. This objective in this paper is to determine the production lot size while minimizing the total cost per unit of time per unit of time. Various special cases are presented. Two of them are extensions of results obtained previously in the literature. Finally, a numerical example is given which uses a discrete Weibull probability distribution. Sensitivity analysis of the model with respect to cost and time parameters is also performed.     

A new EPQ model: integrating lower pricing,rework and reject situations

The economic production quantity (EPQ) is a well-known and commonly used inventory control technique. It has been used for well over 50 years to optimize lot sizes in transportation/production. The standard results are easy to apply but are based on a number of assumptions. A common assumption in the EPQ model is that all units produced are of perfect quality, this will underestimate the actual required quantity. Many researchers have studied the effects after relaxing this assumption on the EPQ model. The previous studies had considered that imperfect quality and defective items are either to be reworked instantaneously and kept in stock or rejected at a cost. The objective of this paper is to provide a framework to integrate lower pricing, rework and reject situations into a single EPQ model. A 100% inspection is performed in order to identify the amount of good quality items, imperfect quality items and defective items in each lot. This model assumes that items of imperfect quality, not necessarily defective, could be used in another production situation or sold to a particular purchaser at a lower price. The electronic and clothing industries give good examples for such situations. A mathematical model is developed and a numerical example is presented to illustrate the solution procedures. It is found that the time factor of when to sell the imperfect items is critical, as this decision will affect the inventory cost and the batch quantities.     

A simple integrated production policy of an imperfect item for vendor and buyer

This article develops a simple approach for determining an optimal integrated vendor–buyer inventory policy for an item with imperfect quality. The objective is to minimize the total joint annual costs incurred by the vendor and the buyer. This model is assumed to produce a certain number of defective items during the production process. Items of poor quality detected in the screening process of a lot are sold at a discounted price. The expected annual integrated total cost function is derived and a solution procedure is proposed to determine the optimal policy. Finally, a numerical example is also given to illustrate the solution procedure presented in this article.     

Coordinating replenishments in a supply chain with quality control considerations

We study the impact of coordinated replenishment, a popular supply chain initiative, on a quality control system. We use the (Q, S) policy to manage a two-item inventory control system. If the items are jointly replenished, the number ordered for each item varies from lot to lot. As the number varies, the sampling plan will also be changed. Companies have to determine sampling plans to minimize quality cost when the order is mixed with several items and the number of each item varies from order to order. Management's primary concern is to determine the optimal sampling sizes and acceptance numbers for all items in an order.     

Lowering Inventory Systems Costs by Using Regression-Derived Estimators of Demand Variability*

Scientific techniques for inventory management typically are applied to systems containing many items. Such techniques require an estimation of the demand variance (and mean) of each item from historical data. This research demonstrates a significant potential for improvement in system cost performance from using least-squares regression fits of a variance-to-mean functional relation instead of the standard statistical variance estimate. Even when there is a moderate degree of heterogeneity among items and when the form of the variance-to-mean relation is misspecified, substantial cost savings may be realized. The cost of statistical uncertainty may be reduced by half. The research also provides evidence that system cost is fairly insensitive to the number of items used to fit the regression. This paper provides the underlying reason why a regression-derived variance estimator yields lower cost: it is less variable than the usual individual item variance estimator.     

带学习效应的双渠道供应链库存策略研究

针对具有学习行为的双渠道供应链问题,本文研究了两种分销渠道并存下的最优库存策略。有限计划期内,分销商通过传统销售和在线销售来满足下游顾客的需求。两种分销渠道下的销售单价为时变不减线性函数,当系统中各周期的生产订购固定成本以一定的概率具有学习效应行为时,分别建立了非变质产品生产存贮问题的混合整数约束优化模型以及易变质产品存贮问题的无约束混合整数优化模型,所建立模型的目标为极大化分销商总利润函数。对于这两类模型,通过分析其最优解的性质,利用将生产订购次数松弛为连续变量的技巧证明了最优解存在的唯一性。给出了最优策略的求解方法并比较了两类模型最优利润函数值的大小。最后通过数值算例对上述模型进行了验证,数值结果表明当供应链系统中存在学习效应行为时,该系统能够获得更多的利润。     

Determination of economic production quantity in a multi-stage production system

In this paper two models have been suggested for determining economic production quantity in a multi-stage production system. The demand for the product is assumed constant and it is supplied by manufacturing the product in equal production runs. The production lot is transported in a number of sub-batches of equal sizes. Each sub-batch is processed on the production stages without wait during process. As a result of processing the sub-batches without wait during process, the processing on the production stages is interrupted. Expressions have been derived for the manufacturing cycle time, the total process inventory and the finished product inventory and then total variable cost models have been suggested and manipulated for obtaining the economic production quantity.     

An efficient FPRAS type group testing procedure to approximate the number of defectives

In many fault detection problems, we want to detect or identify defective items in a sample set by using the minimum number of tests. Group testing is for the scenario where each test is on a subset of items, and tells whether the subset contains at least one defective item or not. Another practically important problem is to estimate the number of defective items in a sample set. In this paper, we present an efficient FPRAS (fully polynomial-time randomized approximation scheme) type group testing procedure to approximate the number of defective items in a sample set.     

Production lot sizing with process deterioration and machine breakdown under inspection schedule

The paper develops integrated production, inventory and maintenance models for a deteriorating production system in which the production facility may not only shift from an ‘in-control’ state to an ‘out-of-control’ state but also may break down at any random point in time during a production run. In case of machine breakdown, production of the interrupted lot is aborted and a new production lot is started when the on-hand inventory is depleted after corrective repair. The process is inspected during each production run to examine the state of the production process. If it is found in the ‘in-control’ state then either (a) no action is taken except at the time of last inspection where preventive maintenance is done (inspection policy-I) or (b) preventive maintenance is performed (inspection policy-II). If, however, the process is found to be in the ‘out-of-control’ state at any inspection then restoration is done. The proposed models are formulated under general shift, breakdown and repair time distributions. As it is, in general, difficult to find the optimal production policy under inspection policy-I, a suboptimal production policy is derived. Numerical examples are taken to determine numerically the optimal/suboptimal production policies of the proposed models, to examine the sensitivity of important model parameters and to compare the performance of inspection and no inspection policies.     

Quality strategies in supply chain alliances of disposable items

This paper studies a single-product distribution channel where a supplier manufactures items of a given type, some of which are defective, that are sold by a retailer who only detects a subset of the defective items, passing the rest along to customers. We conjecture the structure of the demand and cost functions, assuming customers to have a decreasing marginal aversion to bad quality while both the supplier and the retailer make marginally increasing efforts to avoid bad quality. This allows us to deduce several implicit parameters of a cost model based on observable data, such as the share of the channel margin. Once the parameters of the model are available, we analyze the result of vertical integration. Although we confirm the well-known fact that vertical integration improves the quality perceived by the customer, we characterize the supplier's decision of whether or not to provide a better quality in terms of the individual channel margins. As an alternative, we derive the conditions under which the supplier and the retailer may devise a mutually beneficial transfer contract that simultaneously increases their profit and improves quality.     

Improved adaptive group testing algorithms with applications to multiple access channels and dead sensor diagnosis

We study group-testing algorithms for resolving broadcast conflicts on a multiple access channel (MAC) and for identifying the dead sensors in a mobile ad hoc wireless network. In group-testing algorithms, we are asked to identify all the defective items in a set of items when we can test arbitrary subsets of items. In the standard group-testing problem, the result of a test is binary—the tested subset either contains defective items or not. In the more generalized versions we study in this paper, the result of each test is non-binary. For example, it may indicate whether the number of defective items contained in the tested subset is zero, one, or at least two. We give adaptive algorithms that are provably more efficient than previous group testing algorithms. We also show how our algorithms can be applied to solve conflict resolution on a MAC and dead sensor diagnosis. Dead sensor diagnosis poses an interesting challenge compared to MAC resolution, because dead sensors are not locally detectable, nor are they themselves active participants. A preliminary version of this paper was presented at SPAA 2006.     

Simultaneous determination of production lot size and process parameters under process deterioration and process breakdown

The purpose of this study is to combine production-inventory management with process-quality design for determining production lot size and process parameters under the possibility of process deterioration and breakdown. The total cost of such an integrated model includes: the combined setup cost (production setup and process resetting), the costs of quality loss, tolerance and mean costs for processes established, a penalty cost for process breakdown and carrying costs for cumulated inventory. The quadratic quality loss function is introduced to assess quality loss within the system. Decision variables include the initial setting (process mean) and process tolerance for process parameters determination, and production lot size for production-inventory management. The cycle time for production-inventory management is assumed to be the same as the resetting cycle for the new process-quality system. The contribution of this study lies in its development of an integrated model that enables process parameters, production lot size, and cycle time to be determined concurrently for quality and economic considerations, and at an earlier time in the process design and production management stage. An example is presented to demonstrate the proposed model.     

Impact of investing in quality improvement on (Q,r, L) model involving the imperfect production process

This paper investigates the impact of quality improvement on the modified lot size reorder point models involving variable lead time and partial backorders. The formulated models include the imperfect production process and an investing option of improving the process quality. The objective is simultaneously optimizing the lot size, reorder point, process quality level and lead time. We first assume that the lead time demand follows a normal distribution, then relax this assumption to consider the distribution-free case where only the mean and standard deviation of lead time demand are known. An algorithm procedure of finding the optimal solution is developed, and two numerical examples are given to illustrate the results.     

基于批量流的多阶段生产系统的优化问题研究

考虑一个多阶段生产系统,在每个阶段上生产批量被分成若干个子批量进行加工,子批量可以相等也可以不相等,同时每个阶段上在相邻子批量之间可以有空闲。每个阶段上子批量的数目可以不相等。文中首先以系统总变动成本为目标函数对这样一个系统建立对应的模型,提出了求解这一问题的启发式方法,通过数值算例验证了这一方法的有效性。此外,还讨论了重启成本、空闲成本和对应于子批量的调整成本对系统总变动成本、生产批量以及子批量数目的影响。     

The Impact of Imperfect Processes on Production Run Times

This paper investigates the interaction between the economics of production and imperfections in the production process. Specifically, this paper is the first to devise a model in an attempt to provide managers with guidelines to choose the appropriate production run times to buffer against both the production of defective items and stoppages occurring due to machine breakdowns. In addition to providing several structural properties of the model, we show that a manager will always incur a cost penalty when (s)he uses the results of two oft‐cited models‐the EMQ (Economic Order/Manufacturing Quantity) and the NR‐E (No‐Resumption, Exponential machine breakdown)‐to determine production run times.     

A Single‐Period Assortment Optimization Model

This paper studies a single‐period assortment optimization problem with unequal cost parameters. The consumer choice process is characterized by a Multinomial Logit (MNL) model. When the store traffic is a continuous random variable, we explicitly derive the structure of the optimal assortment. Our approach is to use a comprehensive measure–profit rate to evaluate the profitability of each variant and then determine which product should be offered. We demonstrate that the optimal assortment contains the few items that have the highest profit rate. When the store traffic is discrete, the optimal solution is difficult to obtain. We propose a “profit rate” heuristic, which is inspired by the result for the case of continuous store traffic. In a special case with equal cost parameters and normal demand distribution, the profit rate heuristic is indeed optimal. Using randomly generated data, we test the effectiveness of the heuristic and find that the average percentage error is less than 0.1% and that the hit rate is above 90%. Our research provides managerial insights on assortment planning and accentuates the importance of measuring the profitability of each product when the demand is random and cannibalization among different products exists.     

A cost model for deferred state life test plans with replacement

This paper presents a cost model for the deferred state life test plan, which is one of the lot-by-lot acceptance sampling plans by attributes. In most sampling plans, the decision to accept or reject a submitted lot depends only on the sampling test results of the lot concerned; other information will not be considered. Deferred state life test plan is a sampling plan which uses information about subsequent lots for making decisions to accept or reject the current lot. The objective of this paper is to evaluate the total test cost of using the deferred state life test plan to see whether the use of this life test plan can reduce the total cost of the sampling test. In order to calculate the expected total test cost of the deferred state life test plan, a cost model is developed for the deferred state life test plan with replacement. Also, a cost comparison is made between a deferred state life test plan and a comparable military standard sampling plan which offers the same level of producer's and consumer's protection. The results show that the deferred state life test plan consistently reduces the overall cost of sampling tests over a variety of test conditions.     

缺陷品可完全退货的库存控制模型的研究

本文对包含缺陷产品且对其采取完全退货策略的库存问题进行了研究.假设缺陷率服从均匀分布,以销售利润为目标函数,建立了考虑退货的缺货库存模型,通过优化求解获得最优订货量和最大销售利润.最后通过仿真分析研究了缺陷率对订货量和销售利润的影响.     

ON-LINE QUALITY MANAGEMENT: INTEGRATION OF PRODUCT INSPECTION AND PROCESS CONTROL

A growing recognition that quality management is an important factor in defining a firm's competitive position has led to renewed attention to this function and has resulted in implementation of elaborate systems for on-line quality control comprising product inspection and process control. Traditionally, these functions have been treated independently, with very little interaction. In this paper we examine, in detail, a scheme that integrates the two functions, and we demonstrate that such an approach can result in significant cost savings. The motivation for this work comes from our experience in a wafer fabrication facility that suggested that exchange of quality information between different stages of production could result in significant performance improvements. To illustrate this approach, we consider a specific environment characterized by a single-stage continuous production process whose status is monitored by an X̄ control chart. We assume that quality-related costs may be described as a function of the process output. This is analogous to Taguchi's quality loss function and may be interpreted as a generalization of conventional classification of process output as either acceptable or defective units. The integrative scheme essentially relies on utilization of the process status information (based on process control) in making product inspection decisions. For this system we derive a cost model and develop a solution procedure to determine optimal decision parameters. Limited computational results indicate that the scheme has significant potential for reducing quality-related costs.     

风险质检行为下的模糊生产-库存决策

本文研究在风险质检行为下需求与生产率具有模糊属性的由一个制造商与一个零售商构成的生产-库存问题。在假设制造商生产的产品存在质量缺陷,零售商在质检过程中存在质检风险的基础上,分别建立了需求模糊下的生产-库存总成本模型,需求与生产率模糊下的总成本模型,运用符号距离法进行了逆模糊化处理,将模糊化的生产-库存总成本转化为确定性成本。证明了两类情形下的总成本均是关于最优订购量与最优缺货量的联合凸函数。数值分析结果表明：随着期望缺陷率的增加,最优订购量增加,最优缺货量减少,最优成本增加,且最优成本增加的速度越来越快。一类质检风险增大引起总成本增加,二类质检风险增大引起总成本减少。最优订购策略对质检一类风险敏感,对质检二类风险不敏感。