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A Single-Stage Manufacturing Model with Imperfect Items, Inspections, Rework, and Planned Backorders

Author

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  • Chang Wook Kang

    (Department of Industrial and Management Engineering, ERICA Campus, Hanyang University, Ansan, Gyeonggi-do 15588, Korea)

  • Misbah Ullah

    (Department of Industrial Engineering, University of Engineering and Technology, Peshawar 25000, Pakistan)

  • Mitali Sarkar

    (Department of Industrial and Management Engineering, ERICA Campus, Hanyang University, Ansan, Gyeonggi-do 15588, Korea)

  • Muhammad Omair

    (Department of Industrial Engineering, Jalozai Campus, University of Engineering and Technology, Peshawar 25000, Pakistan)

  • Biswajit Sarkar

    (Department of Industrial and Management Engineering, ERICA Campus, Hanyang University, Ansan, Gyeonggi-do 15588, Korea)

Abstract

Each industry prefers to sell perfect products in order to maintain its brand image. However, due to a long-run single-stage production system, the industry generally obtains obstacles. To solve this issue, a single-stage manufacturing model is formulated to make a perfect production system without defective items. For this, the industry decides to stop selling any products until whole products are ready to fulfill the order quantity. Furthermore, manufacturing managers prefer product qualification from the inspection station especially when processes are imperfect. The purpose of the proposed manufacturing model considers that the customer demands are not fulfilled during the production phase due to imperfection in the process, however customers are satisfied either at the end of the inspection process or after reworking the imperfect products. Rework operation, inspection process, and planned backordering are incorporated in the proposed model. An analytical approach is utilized to optimize the lot size and planned backorder quantities based on the minimum average cost. Numerical examples are used to illustrate and compare the proposed model with previously developed models. The proposed model is considered more beneficial in comparison with the existing models as it incorporates imperfection, rework, inspection rate, and planned backorders.

Suggested Citation

  • Chang Wook Kang & Misbah Ullah & Mitali Sarkar & Muhammad Omair & Biswajit Sarkar, 2019. "A Single-Stage Manufacturing Model with Imperfect Items, Inspections, Rework, and Planned Backorders," Mathematics, MDPI, vol. 7(5), pages 1-18, May.
    • Handle: RePEc:gam:jmathe:v:7:y:2019:i:5:p:446-:d:232524
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    References listed on IDEAS

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    Cited by:

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    2. Singa Wang Chiu & Liang-Wei You & Tsu-Ming Yeh & Tiffany Chiu, 2020. "The Collective Influence of Component Commonality, Adjustable-Rate, Postponement, and Rework on Multi-Item Manufacturing Decision," Mathematics, MDPI, vol. 8(9), pages 1-18, September.
    3. Rimi Karmakar & Sanat K. Mazumder & Md Billal Hossain & Csaba Balint Illes & Arindam Garai, 2023. "Sustainable Green Economy for a Supply Chain with Remanufacturing by Both the Supplier and Manufacturer in a Varying Market," Logistics, MDPI, vol. 7(3), pages 1-48, July.
    4. Waqas Ahmed & Muhammad Jalees & Muhammad Omair & Zainab Mukhtar & Muhammad Imran, 2022. "An inventory management for global supply chain through reworking of defective items having positive inventory level under multi-trade-credit-period," Annals of Operations Research, Springer, vol. 315(1), pages 1-28, August.
    5. Monica Aureliana Petcu & Liliana Ionescu-Feleaga & Bogdan-Ștefan Ionescu & Dumitru-Florin Moise, 2023. "A Decade for the Mathematics : Bibliometric Analysis of Mathematical Modeling in Economics, Ecology, and Environment," Mathematics, MDPI, vol. 11(2), pages 1-30, January.

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