Advances in Industrial Engineering

Advances in Industrial Engineering

Simultaneous Analysis of Quality, Inventory and Maintenance Costs by Considering Rework in Single-Machine Production System

Document Type : Research Paper

Authors
Seyed Mohammad Hassan Hosseini 1
Parviz Fattahi 2
1 Associate Professor, Department of Industrial Engineering and Management, Shahrood University of technology, Shahrood, Iran.
2 Professor, Department of Industrial Engineering, Faculty of Engineering, Alzahra University, Tehran, Iran.
10.22059/aie.2025.384115.1921
Abstract
Equipment failure leads to non-conforming products and there is usually a direct relation between the failure rates and the amount of the non-conforming products. Inventory is another issue for production managers and so, they should provide an optimum condition between these related issues. This paper aims to investigate the policies of maintenance, quality control, and inventory in a single machine production system simultaneously with the aim of minimizing total costs. To close the problem to practical condition, machine failures are considered under uncertainty with a known distribution probability. The maintenance time is assumed dependent on the maximum non-conforming products produced per unit and the amount of buffer stock. Moreover, the non-conforming products can be reworked in an additional work station. The problem is formulated and modeled under different various scenarios considering three kinds of cost including quality control, inventory, and maintenance. To test the proposed model, four scenarios are investigated for a numerical example consists of: production period without shortage, production period with compensable shortage, production period before the buffer stock with compensable shortage, and time-based cost analysis. Finally, result analysis has been presented that demonstrates proper efficiency of the proposed model in cost reduction.
Keywords
Integrated Production Control Model
Quality Control
Maintenance
Inventory
Rework
Subjects
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Advances in Industrial Engineering
Volume 59, Issue 1
June 2025
Pages 183-197