Optimal production cycles, procurement schedules, and joint investment in an imperfect production system

In this paper, we consider the simultaneous determination of production cycles for the end product, procurement schedules for its input materials, and joint investment in setup reduction and process quality improvement for a production system with imperfect production processes. In the analysis, we assume that setup reduction and process quality are functions of capital expenditure and that the input materials, which are purchased from outside suppliers, are gradually converted into the product during manufacture. We derive a solution procedure to find the optimal production cycle time, procurement schedules, joint investment, and the corresponding total relevant cost. We present numerical examples to illustrate the procedure and to delineate the relationships among production cycle times for the end product, the procurement schedules for its input materials, and setup reduction and quality improvement.     

Setup cost reduction in (<Emphasis Type="Italic">Q,r</Emphasis>) policy with lot size,setup time and lead-time interactions

It is often assumed in most deterministic and stochastic inventory models that lead-time is a given parameter and the optimal operating policy is determined on the basis of this unrealistic assumption. However, the manufacturing lead-time is made up of several components (moving time, waiting time, setup time, lot size, and rework time) most of which should be treated as controllable variables. In this paper the effect of setup cost reduction is addressed in a stochastic continuous review inventory system with lead-time depending on lot size and setup time. An efficient iterative procedure is developed to determine the near optimal lot size, reorder point and setup time. Furthermore, a sensitivity analysis is carried out to assess the cost savings that can be realised by investing in setup.     

On the Effect of Product Variety in Production–Inventory Systems

In this paper, we examine the effect of product variety on inventory costs in a production–inventory system with finite capacity where products are made to stock and share the same manufacturing facility. The facility incurs a setup time whenever it switches from producing one product type to another. The production facility has a finite production rate and stochastic production times. In order to mitigate the effect of setups, products are produced in batches. In contrast to inventory systems with exogenous lead times, we show that inventory costs increase almost linearly in the number of products. More importantly, we show that the rate of increase is sensitive to system parameters including demand and process variability, demand and capacity levels, and setup times. The effect of these parameters can be counterintuitive. For example, we show that the relative increase in cost due to higher product variety is decreasing in demand and process variability. We also show that it is decreasing in expected production time. On the other hand, we find that the relative cost is increasing in expected setup time, setup time variability and aggregate demand rate. Furthermore, we show that the effect of product variety on optimal base stock levels is not monotonic. We use the model to draw several managerial insights regarding the value of variety-reducing strategies such as product consolidation and delayed differentiation.     

The effect of product variety on supply-chain performance

We present a stylized model for analyzing the effect of product variety on supply-chain performance for a supply chain with a single manufacturer and multiple retailers. The manufacturer produces multiple products on a shared resource with limited capacity and the effect of changeovers on supply-chain cost is due primarily to setup time rather than setup cost. We show that the expected replenishment lead time and the retailers' costs are concave increasing in product variety and that the increase is asymptotically linear. Thus, if setup times are significant, the effect of product variety on cost is substantially greater than that suggested by the risk-pooling literature for perfectly flexible manufacturing processes, where the cost increases proportionally to the square root of product variety. We demonstrate that disregarding the effect of product variety on lead time can lead to poor decisions and can lead companies to offer product variety that is greater than optimal. The results of our analysis enable decision-makers to quantify the effect of product variety on supply-chain performance and thus to determine the optimal product variety to offer. The results can also be used to evaluate how changes in the manufacturing process, the supply-chain structure, and the customer demand rate can improve the performance of supply chains with high product variety.     

Optimal pricing,EOL (end of life) warranty,and spare parts manufacturing strategy amid product transition

We study firm’s strategy to determine its product price and warranty period, and plan the spare parts manufacturing so as to maximize its profit and at the same time to fulfill its commitment to providing the customer with the key part continuously over the relevant decision time horizon, i.e., the product’s life cycle plus its EOL service (warranty) period. To examine the research question, we develop and solve a two-stage optimal control theory model. From the numerical analysis, we infer as follows. It is not always true that the longer the EOL warranty period, the better for the company’s profitability, implying there exists an optimal EOL warranty period that balances all the relevant forces like market demand and cost structures. The relationship between optimal EOL warranty period and failure rate (defect rate) is concave: when the defect rate is moderate, the company has to increase its EOL warranty period as the defect rate increases so as to compensate for the deteriorating quality; but, when the defect rate is beyond a threshold level, the company needs to curtail its EOL warranty commitment as the defect rate increases in order to avoid excessive cost to service the failed parts. By depicting key dynamics in this managerial problem, this paper sheds light on how to make decision for optimal pricing and warranty when the product life cycle is finite and the company is obliged to provide after-sales services to customers for an extended period of time after the current product is no longer produced.     

Metaheuristic algorithms for balancing robotic assembly lines with sequence-dependent robot setup times

Industries are incorporating robots into assembly lines due to their greater flexibility and reduced costs. Most of the reported studies did not consider scheduling of tasks or the sequence-dependent setup times in an assembly line, which cannot be neglected in a real-world scenario. This paper presents a study on robotic assembly line balancing, with the aim of minimizing cycle time by considering sequence-dependent setup times. A mathematical model for the problem is formulated and CPLEX solver is utilized to solve small-sized problems. A recently developed metaheuristic Migrating Birds Optimization (MBO) algorithm and set of metaheuristics have been implemented to solve the problem. Three different scenarios are tested (with no setup time, and low and high setup times). The comparative experimental study demonstrates that the performance of the MBO algorithm is superior for the tested datasets. The outcomes of this study can help production managers improve their production system in order to perform the assembly tasks with high levels of efficiency and quality.     

An EPQ model with setup cost and process quality as functions of capital expenditure

This paper considers an economic production quantity (EPQ) model with imperfect production processes, in which the setup cost and process quality are functions of capital expenditure. The mathematical model is derived to investigate the effects of an imperfect production process on the optimal production cycle time when capital investment strategies in setup reduction and process quality improvement are adopted. An efficient procedure is developed to find the optimal production run length, setup cost and process quality. Finally, a numerical example is provided to illustrate the theoretical results. Some managerial implications are also included.     

Economic lot scheduling with uncontrolled co-production

The aim of this paper is to analyze the effects of uncontrolled co-production on the production planning and lot scheduling of multiple products. Co-production occurs when a proportion of a certain production comes out as another product. This is typical in the process industry where quality and process specifications can lead to diversified products. We assume that there is no demand substitution and each product has its own market. Furthermore, we assume that co-production cannot be controlled due to technical and/or cost considerations. We introduce two models that extend the common cycle economic lot scheduling (ELSP) setting to include uncontrolled co-production. In the first model we do not allow for shortages and derive the optimal cycle time expression. In the second model, we allow for planned backorders and characterize the optimal solution in closed form. We provide a numerical study to gain insight about co-production. It seems that the cycle time increases with co-production rate and utilization of the system. The effect of co-production on long-term average cost does not exhibit a certain characteristic.     

Impact of flexible machines on automated manufacturing systems

Although the problem of scheduling dynamic job shops is well studied, setup and changeover times are often assumed to be negligibly small and therefore ignored. In cases where the product mix changes occur frequently, setup and changeover times are of critical importance. This paper applies some known results from the study of multi-class single-server queues with setup and changeover times to develop an approximation for evaluating the performance of job shops. It is found that the product mix, setup and changeover times, and scheduling rules affect the performance significantly, in particular at high levels of machine utilisation. This approach could be used to determine the required level of flexibility of machines and to choose an appropriate scheduling policy such that production rates remain within acceptable limits for foreseeable changes in the product mix.     

Optimal investment in setup reduction in manufacturing systems with WIP inventories

A number of models have been proposed to predict optimal setup times, or optimal investment in setup reduction, in manufacturing cells. These have been based on the economic order quantity (EOQ) or economic production quantity (EPQ) model formulation, and have a common limitation in that they neglect work-in-process (WIP) inventories, which can be substantial in manufacturing systems. In this paper a new model is developed that predicts optimal production batch sizes and investments in setup reduction. This model is based on queuing theory, which permits it to estimate WIP levels as a function of the decisions variables, batch size and setup time. Optimal values for batch size and setup time are found analytically, even though the total cost model was shown to be strictly non-convex.     

Scheduling in bicriteria single machine systems with past-sequence-dependent setup times and learning effects

Scheduling with setup times and learning plays a crucial role in today's manufacturing and service environments where scheduling decisions are made with respect to multiple performance criteria rather than a single criterion. In this paper, we address a bicriteria single machine scheduling problem with job-dependent past-sequence-dependent setup times and job-dependent position-based learning effects. The setup time and actual processing time of a job are respectively unique functions of the actual processing times of the already processed jobs and the position of the job in a schedule. The objective is to derive the schedule that minimizes a linear composite function of a pair of performance criteria consisting of the makespan, the total completion time, the total lateness, the total absolute differences in completion times, and the sum of earliness, tardiness, and common due date penalty. We show that the resulting problems cannot be solved in polynomial time; thus, branch-and-bound (B&B) methods are proposed to obtain the optimal schedules. Our computational results demonstrate that the B&B can solve instances of various size problems with attractive times.     

Joint optimization of process improvement investments for supplier–buyer cooperative commerce

This research focuses on supporting the formation of strategic alliances through the concept of cooperative commerce, where suppliers and buyers work together to jointly optimize their business. The general goal of this research is to examine existing cooperative commerce models for obstacles that would hinder their successful implementation into modern industrial applications and to address those shortcomings. Total annual cost equations are formulated to capture the joint total relevant cost of cooperative commerce business relationships. These total joint relevant cost models will include terms that capture the ordering cost, holding cost, and cost of quality, as well as any applicable investment cost for process improvements, consistent with traditional economic order quantity and economic production quantity theory. This research corrects a modelling/computational error found in the literature that led to underestimation of the effectiveness of process improvements in joint economic lot size models by 5–12%. In addition, the models are expanded to accommodate a full range of product quality inspection policies, from 0 to 100% product inspections. Furthermore, the models are modified to account for the cost of scrap generation, as well as the effects of accepting non-conforming product and rejecting conforming product during quality inspections. Once the total cost models are expanded to account for these neglected costs, the joint total relevant cost equations are minimized to find the optimal batch sizes, and the effects of each model extension on the model solution are studied. Results indicate that these extensions have a significant impact on the model results, such as reduced optimal batch sizes and increased optimal fraction conforming product.     

Optimal production control of a dynamic two-product manufacturing system with setup costs and setup times

This paper deals with the optimal control of a one-machine two-product manufacturing system with setup changes, operating in a continuous time dynamic environment. The system is deterministic. When production is switched from one product to the other, a known constant setup time and a setup cost are incurred. Each product has specified constant processing time and constant demand rate, as well as an infinite supply of raw material. The problem is formulated as a feedback control problem. The objective is to minimize the total backlog, inventory and setup costs incurred over a finite horizon. The optimal solution provides the optimal production rate and setup switching epochs as a function of the state of the system (backlog and inventory levels). For the steady state, the optimal cyclic schedule is determined. To solve the transient case, the system's state space is partitioned into mutually exclusive regions such that with each region, the optimal control policy is determined analytically.     

Recovery decisions of a producer in a legislative disposal fee environment

The main objectives of the environmental legislation originating from extended producer responsibility (EPR) principle are to lead producers to undertake recovery initiatives for their end-of-use products and to promote environmentally desirable product design. It is still controversial whether current implementations of EPR principle are effective in attaining these objectives. This study seeks to answer the following questions: (1) What is the impact of EPR legislation on the product recovery decisions of producers? (2) How do the redesign opportunities (i.e., design for disassembly) affect the willingness of producers for product recovery? (3) How do the investment needs to start recovery practices and the reluctance of producers to allocate sufficient funds for this purpose affect the optimal recovery decisions? We use stylized economic models to represent the implementation in practice and solving our models we obtain closed form and numerical solutions that help us to see the impact of various parameters on the optimal decisions of a producer. Our findings indicate that redesign opportunities encourage producers for more recovery, however the reluctance of producers to cover the initial investments may substantially reduce the effectiveness of the legislation and the recovery amounts.     

A general approximation for the single product lot sizing model with queueing delays

The objective of this paper is to derive a general approximation for the single product lot sizing model with queueing delays, explicitly including a non-zero setup time. Most research focuses on bulk (batch) arrival and departure processes. In this paper we assume an individual arrival and departure process allowing the modelling of more realistic demand patterns. A general approximation of the expected lead time and the variance of the lead time is derived. The lead time probability distribution is approximated by means of a lognormal distribution. This allows the manufacturer to quote lead times satisfying a specified customer service level as a function of the lot size. The main result is a convex relationship of the expected lead time and the quoted lead time as a function of the lot size. The results are illustrated by means of numerical examples.     

Heuristic Approaches for a Scheduling Problem in the Plastic Molding Department of an Audio Company

A production scheduling problem for making plastic molds of hi-fi models is considered. The objective is to minimize the total machine makespan in the presence of due dates, variable lot size, multiple machine types, sequence dependent, machine dependent setup times, and inventory limits. Goal programming and load balancing are applied to select the set of machine types and assign mold types to machines, resulting in a set of single-machine scheduling problems. A mixed-integer program (MIP) is formulated for the general problem but could solve only small instances. A single-machine scheduling heuristic is designed to adopt a production sequence from a travelling salesman solution. The start time of every cycle is determined by a simplified MIP. Production cycles are defined to equalize the stockout times of mold types. A post-processing step reduces the number of setups in the last cycle. Results using real-life data are promising. Characteristics giving rise to high machine utilization are discussed.     

具有非线性采购成本库存控制问题的研究现状与挑战

库存管理是基于运筹学而发展起来的一门学科,并成为近几十年来运筹学和管理科学重要的研究领域之一。在库存系统中,采购成本是必不可少的成本之一,主要包含产品成本、运输成本、装卸成本等。现实中,采购成本依赖于采购量,且往往是采购量的非线性函数。介绍了几类常见的采购成本函数：依赖于采购量的固定成本、增量折扣、全量折扣、车载容量折扣和凸采购成本等。基于周期盘点库存模型和连续盘点库存模型,综述了带有这些非线性采购成本函数的库存模型研究进展。虽然经过了几十年的研究,但很多带有非线性采购成本的库存模型的最优采购策略因为其复杂性至今未能被完整刻画。通过综述来简单讨论该类问题的挑战和机会。     

An analysis of setup cost reduction in a two stage system

This paper investigates the impact of investing in setup cost reduction in a two stage manufacturing process. Closed form relationships are developed for the cases of investment in primary stage setup cost reduction, investment in finishing stage setup cost reduction, and simultaneous investment in setup cost reduction in both stages. Numerical results are presented which compare each of the models to the basic model. These results indicate that when investment in both stages is feasible, it is most effective to simultaneously invest in setup cost reduction. Failing this, the next best alternative is to invest in setup cost reduction in the finishing stage.     

A hybrid heuristic and linear programming approach to multi-product machine scheduling

A new heuristic approach is presented for scheduling economic lots in a multi-product single-machine environment. Given a pre-defined master sequence of product setups, an integer linear programming formulation is developed which finds an optimal subsequence and optimal economic lots. The model takes explicit account of initial inventories, setup times and allows setups to be scheduled at arbitrary epochs in continuous time, rather than restricting setups to a discrete time grid. We approximate the objective function of the model and solve to obtain an optimal capacity feasible schedule for the approximate objective. The approach was tested on a set of randomly generated problems, generating solutions that are on average 2.5% above a lower bound on the optimal cost. We also extend the approach to allow shortages.     

Solution strategies for multi-stage wafer probing scheduling problem with reentry

The multi-stage wafer probing scheduling problem (M-WPSP) with reentry is a practical variation of the parallel-machine scheduling problem. Since the M-WPSP involves multiple product families, to be processed on multiple stages, with various job due dates, ready times, reentry, serial and batch operations, sequential-dependent setup time, it is more difficult to solve than the classical parallel-machine scheduling problems. In this paper, we consider two strategies to solve the M-WPSP with reentry, where the total machine workload must be minimized. These two strategies incorporate a global planning mechanism, in advance, to determine the required stage due date of job at each process stage to prevent the due date problems occurring at the final stage. The sequential strategy schedules the jobs at the required stages according to the sequence of manufacturing process. The parallel strategy is designed specifically for the reentrant characteristic. To evaluate the efficiency of the proposed strategies, a set of test problems involving four critical factors, the product family ratio, the temperature-change consideration, the tightness of due dates, and the ready time, are designed to test the quality of solutions under two levels of workload.