An optimal design for process quality improvement: modelling and application

Existing research works on process quality improvement focus largely on the linkages between quality improvement cost and production economics such as set-up cost and defect rate reduction. This paper deals with the optimal design problem for process improvement by balancing the sunk investment cost and revenue increments due to the process improvement. We develop an optimal model based on Taguchi cost functions. The model is validated through a real case study in automotive industry where the 6-sigma DMAIC methodology has been applied. According to this research, the management can adjust the investment on prevention and appraisal costs on quality improvement that enhances process capability, reduces product defect rate and, as a result, generates remarkable financial return.     

Optimal batch size and investment in multistage production systems with scrap

In this paper, we study the problem of selecting the optimum production batch size in multistage manufacturing facilities with scrap and determining the optimal amount of investment. We analyse the effect of investment for quality improvement on the reduction of the proportion of defectives, and the effect of this reduction on processing cost, setup cost, holding cost, and profit loss. The quality characteristic of the product manufactured is assumed to be normally distributed with a mean equal to the target value. The purpose of the investment is to reduce the variance of the quality characteristic and hence the proportion of defectives. The model assumes known demand, which must be satisfied completely, scrappage at each stage and profit loss due to scrap. Using this model, the optimal values of the production quantity and the proportion of defectives for minimizing the total cost are obtained. The optimal investment is then obtained using the relationship between the investment and the proportion of defectives.     

消费者反馈下企业质量改进投入决策Moran演化分析

基于消费者反馈机制，考虑生产同种产品的N个生产企业质量改进投入决策的演化轨迹。每个生产企业在权衡对消费者反馈的价值感知以及额外质量改进成本后有两种策略选择(质量优势策略或低成本策略)。基于Moran过程的固定点概率，计算出在有限的生产企业群体中，质量优势策略与低成本策略成功侵入的概率。通过对比两种策略的适应度，以及个体固定点概率与中性突变的概率大小，分别得到强选择与弱选择下策略占优的条件，并对结果进行仿真验证。研究发现：1)生产企业数量较少时，无论质量改进成本高低与否，只要消费者对质量水平有反馈并对企业收益造成影响，质量优势策略将占领整个群体；2)当生产企业对消费者反馈的感知效用远远高于额外质量改进成本时，质量优势策略为占优策略；3)对消费者反馈的感知效用略高于额外质量改进成本时，强选择下，质量优势策略占优，然而在弱选择下，占优策略取决于种群数量；4)企业对消费者反馈的重视程度取决于对自身产品的市场定位，本文将为目标定位于维持或占据不同市场份额的企业提供质量改进政策建议与指导。     

Cost/quality tradeoffs for control procedures in information systems

An analytical framework is presented to study the cost/benefit tradeoffs of alternative internal control scenarios designed to ensure quality of outputs from information systems. A mathematical model is used to evaluate the impact that various alternatives have on system performance and cost. The model can be used to compare the benefits gained from enhanced processing with those arising from more effective internal control procedures. Model variables under the control of system designers include placement and effectiveness of internal control procedures, cost and quality of processing activities, both manual and computerized, and cost and quality of correction procedures. The model incorporates a penalty cost incurred by failure to detect and correct errors. The analytical process is illustrated through application to a specific information system.     

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.     

Capacity Investment and Product Line Decisions of a Multiproduct Leader and a Focus Strategy Entrant

In this article, I investigate the capacity investment cost conditions where a multiproduct market leader may respond to a focus strategy entrant by using different strategies such as changing the product mix, production volumes, quality levels, and/or by investing in more capacity. The products offered in the market are quality differentiated and customers are heterogeneous in their willingness to pay for quality. The capacity investment costs of the two firms (i.e., the leader and the entrant) may also be different. The classical Stackelberg model predicts that an incumbent does not change its position in response to entry. However, when heterogeneous customer base, product differentiation, and capacity costs are taken into consideration, I find that the leader with a low capacity cost may choose to expand its product line and increase its production. The leader with low capacity cost may introduce a product that it was holding back when the entrant has to bear the high‐capacity cost and cannibalization threat is relatively small. Nevertheless, the extent of production volume strategies reduces as the capacity cost increases for the leader. I also find that when the leader has the power to set the industry standards by deciding the quality levels, as a response to a high‐quality focused entrant, the leader increases both levels of quality and production of the low‐quality product. Moreover, when the capacity investment cost is high for both the entrant and the leader, I find that market prices may increase with entry.     

OPTIMAL ORDERING IN A DUAL‐SUPPLIER SYSTEM WITH DEMAND FORECAST UPDATES

We study how an updated demand forecast affects a manufacturer's choice in ordering raw materials. With demand forecast updates, we develop a model where raw materials are ordered from two suppliers—one fast but expensive and the other cheap but slow—and further provide an explicit solution to the resulting dynamic optimization problem. Under some mild conditions, we demonstrate that the cost function is convex and twice‐differentiable with respect to order quantity. With this model, we are able to evaluate the benefit of demand information updating which leads to the identification of directions for further improvement. We further demonstrate that the model applies to multiple‐period problems provided that some demand regularity conditions are satisfied. Data collected from a manufacturer support the structure and conclusion of the model. Although the model is described in the context of in‐bound logistics, it can be applied to production and out‐bound logistics decisions as well.     

考虑故障停机的生产控制与维修计划联合决策模型

通过生产控制与维修计划协同决策,降低生产成本。首先描述生产过程,分析各项费用。其次,建立了考虑生产过程失控、故障率和故障停时间的生产过程控制、生产计划优化和维修管理联合优化决策的模型。通过模型求解,联合制定出生产过程检查策略、生产计划（经济生产批量、生产批次）以及维修计划（PM间隔期）,实现单位时间内总费用最低的目标。再次,案例研究,分析生产过程失控、故障率和故障停机时间对于经济生产批量、生产过程检查策略和生产系统维修计划的影响。该模型从理论上解决了生产过程控制、生产计划优化和维修管理联合优化决策难题,对于指导企业制定生产计划和生产系统的检修计划,进而提高产品质量、降低生产成本、确保准时交货都具有指导意义和实用价值。     

The Value of Quality Grading in Remanufacturing

In this paper we consider a tactical production‐planning problem for remanufacturing when returns have different quality levels. Remanufacturing cost increases as the quality level decreases, and any unused returns may be salvaged at a value that increases with their quality level. Decision variables include the amount to remanufacture each period for each return quality level and the amount of inventory to carry over for future periods for both returns (unremanufactured), and finished remanufactured products. Our model is grounded with data collected at Pitney‐Bowes from their mailing systems remanufacturing operations. We derive some analytic properties for the optimal solution in the general case, and provide a simple greedy heuristic to computing the optimal solution in the case of deterministic returns and demand. Under mild assumptions, we find that the firm always remanufactures the exact demand in each period. We also study the value of a nominal quality‐grading system in planning production. Based on common industry parameters, we analyze, via a numerical study, the increase in profits observed by the firm if it maintains separate inventories for each quality grade. The results show that a grading system increases profit by an average of 4% over a wide range of parameter values commonly found in the remanufacturing industry; this number increases as the returns volume increases. We also numerically explore the case where there are capacity constraints and find the average improvement of a grading system remains around 4%.     

THE EFFECT OF LEARNING ON THE OPERATION OF MIXED-MODEL ASSEMBLY LINES

The common approach to balancing mixed-model assembly lines assumes that the line operators are well trained and that the learning effect is negligible. The assumption is that the line operates in steady state over a long period of time. Time-based competition and frequent design changes in many products make this assumption incorrect, and the effect of learning on mixed-model lines should not be neglected. We defined start-up period and developed a model for the line design during start-up. It can be used to evaluate a proposed line design or to develop a feasible line design and to estimate its cost. This proposed model integrates mixed-model learning curves with aggregate planning under learning and a mixed-model line design into a comprehensive framework designed to minimize the total cost of the line during the start-up period.     

A quick response production strategy to market demand

The reason for considering the quick response production strategy to market demand is due to the rapid technology change, which results in decreasing market price and obsolescence. This study considers a production strategy of locating final production line in response to the changes in market demand and the continuous deterioration in stock. The demand rate is assumed to decrease exponentially with time while the price is assumed to decrease linearly with time. The purpose of this study is to derive the most economical site of final-production line that assembles products with short life cycle. The model considered in this research takes into account the sales revenue, the deteriorating cost, the carrying cost, the variable cost and the fixed cost of production. Although there is a higher labour and material cost when the production site is located near market point, the total profit increases due to quicker responsive time, smaller import tax, lower inventory and lesser deteriorating cost.     

质量成本各要素关系研究及模型建立

文章主要针对质量成本各组成部分间的关系以及质量成本与质量水平间的关系做深入分析研究。文章通过建立系统动力学仿真模型来研究不同质量水平下质量成本各组成部分间的关系;质量成本与质量水平的关系研究则利用灰色系统理论解决历史数据不足够多的情况下质量成本与质量水平间的关系,并通过灰色线性回归组合模型建立质量成本与质量水平间的关系模型。首先,文章分析讨论质量成本各组成部分间的三种关系模型;其次,为更进一步深入讨论不同质量水平下质量成本各组成部分间关系,文章建立质量成本各组成部分间的系统动力学模型;再次,文章采用灰色系统模型GM(1,1)与线性相关模型相组合的组合模型并结合新陈代谢处理方法建立一种更为优化的质量成本与质量水平间的关系模型;最后,文章通过案例研究证明质量成本灰色线性回归组合模型的准确性。     

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.     

An aggregate production planning framework for the evaluation of volume flexibility

Flexibility in manufacturing has been identified as one of the key factors to success in the marketplace. Many types of flexibility have been identified in the literature among which volume flexibility is one of the most important. Volume flexibility of a manufacturing system is defined as its ability to be operated profitably at different overall output levels. Volume flexibility permits a manufacturing system to adjust production upwards or downwards within wide limits. In this paper, we develop an aggregate production planning model for volumeflexible production systems. The model can be used with a Monte Carlo simulation to evaluate the optimal level of investment in volume flexibility for a firm operating under a given set of market conditions. In addition, the model can be used to develop some conclusions about the relationship between the value of volume flexibility and the cost of holding inventory, the cost of shortage, forecast accuracy, and the length of the planning horizon.     

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。     

基于厂商理论的区域产业边界和最优要素配置结构

区域经济发展核心是产业结构优化升级和资源的优化配置。在全球经济结构亟待优化升级和要素资源呈现不同层次紧缺的大背景下,如何合理配置和引导区域资源配置,优化产业发展方向,确定包括新兴产业在内的产业发展战略,是每一个地区新形势下面临的重要问题。一方面,在经济全球化和零边际成本趋势驱动下,区域产业发展不再局限于区域内部资源禀赋,资源流动性加强,区域产业发展的选择更加广泛和灵活;另一方面,资源日益短缺和经济快速发展推动了劳动力成本和资本成本上升,产业的生产要素配置也随之变化。基于厂商理论,将区域作为市场经济中的生产主体,在考虑区域交易成本和生产要素成本的基础上,构建区域产业边界模型和产业的最佳要素配置结构模型,开创了资源和商品全球化趋势下的产业升级战略的研究范式,探索了成本约束下的产业生产要素优化配置模式,为经济新常态下的区域产业升级战略和资源配置研究提供理论指引,为区域制定个性化的产业发展战略提供实践依据,同时对零边际成本社会趋势下的产业格局进行了初步的探索。研究得出:产业边界能够在一定程度下反映区域产业长期演化趋势,在完全市场经济下产业边界是产业发展的最优规模;区域产业的要素配置格局取决于产...     

基于卓越绩效模式的供应链质量成本优化研究

本文以供应链质量成本为主要研究对象,分析归纳供应链质量成本研究现状,结合卓越绩效模式方法,提出质量成本核算体系,建立基于卓越绩效模式的供应链质量成本模型。通过一个应用案例,采用遗传算法求解,证明该方法使供应链成本得到了优化。     

引入信息成本的信息结构与股权融资成本

本文放松了Easley和O’Hara信息成本为0的假设,在他们的信息结构模型的理论框架下,构建了一个引入信息成本因素的信息结构模型。从信息结构的四个方面：信息成本、信息风险、信息披露的质量和先验信息质量研究了信息结构与股权融资成本之间的关系,得出了四个推论,从而拓展了信息结构模型。在进一步的实证研究中,选取市场微观结构理论中的逆向选择成本、知情交易概率-PIN分别作为信息成本和信息风险的衡量指标,研究发现：信息成本与股权融资成本之间呈倒‘U’型曲线关系;信息风险越高的股票股权融资成本越高;信息披露质量越高的公司,股权融资成本越低;先验信息质量越高,股权融资成本越低;从而对推论进行了有效验证。本文与Easley和O’Hara最大不同在于引入了信息成本因素,并且用实证方法对推论进行了验证,具有一定的开创性。     

考虑不同回收质量等级的再制造系统回收生产决策

废旧产品的回收再制造过程往往在回收质量、再制造成本、再制造产出率、再制造产品需求等方面存在不确定性因素,极大地增加了再制造生产管理决策的复杂性。本文在一个回收再制造系统中研究了存在多种回收质量等级时的两阶段回收—再制造联合优化决策问题,并扩展到需求与价格相关和再制造产出率随机两种情形。在最大化再制造商期望利润的决策目标下,基于每种回收质量等级的单位回收和再制造成本构造出再制造系统的有效生产前沿面,给出了不同决策情形下再制造商的最优回收数量、销售定价的解析解,并且分析了一些主要的参数对再制造商最优决策的影响。本文的研究结果表明：（1）含有多种回收质量等级的再制造系统中存在一个下凸的有效生产前沿面,不在该前沿面上的任何质量等级的回收产品都将不会被用于再制造;（2）在同等的政府补贴额度下,回收补贴方式对再制造商决策的影响程度大于再制造补贴方式;（3）当再制造品的市场需求与价格相关时,最优销售价格至少大于第一种被使用的回收质量等级的边际回收和再制造成本;（4）任意两种回收质量等级之间存在着替代或互补效应,由其成本差异决定,并且这种效应随着需求不确定性的增大而增大;（5）再制造产出率的不确定性和再制造品需求的不确定性之间存在"对冲"效应,这种效应随着再制造产出率不确定性的降低而减弱。本文的研究可为不确定性环境下再制造企业的回收、生产管理决策提供有益的管理启示。