Title page for ETD etd-0108103-140103

Type of Document Master's Thesis
Author Biswas, Pablo
URN etd-0108103-140103
Title Optimal Batch Quantity Models for A Lean Production System with Rework and Scrap
Degree Master of Science in Industrial Engineering (M.S.I.E.)
Department Industrial and Manufacturing Systems Engineering
Advisory Committee
Advisor Name Title
Bhaba R. Sarker Committee Chair
Dennis B. Webster Committee Member
Lawrence Mann, Jr. Committee Member
  • rework and scrap
Date of Defense 2002-12-03
Availability unrestricted
In an imperfect manufacturing process, the defective items are produced with finished goods. Rework process is necessary to convert those defectives into finished goods. As the system is not perfect, some scrap is produced during this process of rework. In this research, inventory models for a single-stage production process are developed where defective items are produced and reworked, where scrap is produced, detected and discarded during the rework. Two policies of rework processes are considered (a) First policy: rework is done within the cycle, and (b) Second policy: rework is done after N cycles of normal production. Also, three types of scrap production and detection methods are considered for each policy, such as (i) scrap is detected before rework, (ii) scrap is detected during rework and (iii) scrap is detected after rework. Based on these inventory situations, the total cost functions for a single-stage imperfect manufacturing system are developed to find the optimum operational policy. Some numerical examples are provided to validate the model and a sensitivity analysis is carried out with respect to different parameters used to develop the model.
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