Mathematical models for process commonality under quality and resources breakdown in multistage production
It is essential to manage customers’ diverse desires and to keep manufacturing costs as low as possible for survival in competition and eventually in production. Sharing resources in manufacturing for different products is a vital method of accomplishing this goal. The advantages of using a common process in production are stated in the literature. However, the mathematical models as well as simulation or conceptual models are not sufficient. The main objective of this paper is to develop mathematical models for multiproduct and multistage production under quality and breakdown uncertainties. The idea of the process commonality is incorporated in the proposed models. The models are validated by primary data collected from a Malaysian company and comparison of the timely requirement schedules of earlier MRP II and the proposed models under stable and perfect production environments. An appreciable convergence of the outcomes is observed. However, the proposed models are carrying additional information about the available locations of the parts in a time frame. After validation, the effects of process commonality on cost, capacity and the requirement schedule under uncertainties are examined. It is observed that the use of common processes in manufacturing is always better than the non-commonality scenario in terms of production cost. However, the increase in capacity requirement for commonality designs is higher for an ideal system, while it is less when the system suffers from breakdowns and a quality problem.
Key wordsProcess commonality Mathematical model MRP II Quality Breakdown
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