An Integrated Model for Process Selection and Quality Improvement in Multi-Stage Processes (original) (raw)
All production processes produce variance around the desired target value of quality characteristic. This variance affects the product quality level. Accordingly variance reduction needs to be done as the main goal of quality improvement programs. However effort to improve quality of each product unit must take into account to improvement costs. This paper proposes an optimization model for quality improvement in multi-stage processes using a non linear programming model by selecting alternatives process and determining unit of production of each stage to maximize profit as the difference between total income and total relevant cost. Total cost includes manufacturing cost, quality loss cost, rework and scrap cost, and quality improvement implementation cost. This optimization model is implemented in make-to-order manufacturer that produces crimper (a parts of joining plastic packages in packaging machine) which consist of five main stage manufacturing processes. Sensitivity analysis shows that the optimal solution is not sensitive if little changes occur in the constraints scenario. Thus, adding the value constraint on the quality specification, stage capacity, and quality improvement budget will not improve the objective function.
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