1 Determining Quality Inspection Frequency in an Automated Production Line Based on Field Failure Data Analysis (original) (raw)
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Operational Research, 2004
We study the problem of determining the frequency of quality control inspections in a tortilla and bread & bakery manufacturer producing pizzas. We first perform statistical analysis of failure data obtained from a real automated pizza production line. Based on this data, we develop a simple model of a quality inspector who visits several such lines and his goal is to allocate the number of his/her visits to the different workstations of the lines so as minimize the total production time of undetected, defective products.
Modeling cost benefit analysis of inspection in a production line
International Journal of Production Economics, 2014
Production management aims to maximize profit by increasing salable output while reducing the cost related with inspection, where inspection is defined as the measurement and quality assessment of items produced. This study is based on a semiconductor production line with consecutive deteriorating machines. Each machine is inspected via the items it produces and an inspection result triggers a machine's repair, if needed. Inspection related cost includes fixed and variable cost of inspection capacity, Yield Loss Cost generated due to unsalable throughput, and delivery delay cost caused by inspection flow-time. The effects of inspection capacity and inspection rate on cost are investigated using analytical and simulation models. Under a given inspection capacity, Yield Loss Cost decreases with growing inspection rate until a minimum is reached, and then starts to increase with further growing rate. This increase is explained by the impact of higher load on the inspection facility, which prolongs the inspection response time. Thus, an optimal inspection rate can be derived for a given inspection capacity. It will be shown that the higher the capacity, the higher the optimal rate, and the lower the yield loss. Determination of optimal inspection capacity considers the capacity cost against the other costs and minimizes the total expected inspection related costs.
Production Engineering
The assessment of the performance of inspection strategies is a crucial element in the design phase of product quality inspections of manufacturing companies. The aspects that inspection designers need to consider include: (1) the typology of quality inspection, (2) the inspection variables involved, (3) the potential interaction between variables and (4) the presence of inspection errors. In particular, low-volume inspection design is critical due to the lack of historical data and the inadequacy of traditional statistical approaches. By considering these issues, this paper proposes a novel approach to support inspection designers in the prediction of offline quality inspection performance. The development of a probabilistic model based on the analysis of the possible variable interactions and inspection errors and the definition of some performance measures may successfully help designers in the early design stages of inspection process planning. The approach is supported by a pra...
A NEW MODEL FOR PRODUCTION, INSPECTION, AND MAINTENANCE: MODEL VALIDATION AND CASE STUDY
Journal Paper, 2020
A model is developed to integrate production planning, preventive maintenance, and process/product quality inspection decisions. The integrated model objective is to minimize the total costs of the three decisions that are subjected to constraints of production availability, preventive maintenance economical limitations, and system reliability constraints. Genetic Algorithms and Mixed Integer Linear Program are utilized to solve such complicated problems with constraints considered. An extensive literature review has been presented. The integration of the production, preventive maintenance, and quality decisions in one integrated model is rare so that further investigations and real case study applications in the industry fields are needed. The proposed model and solution method are compared and validated with four models and methodologies from literature. A case study demonstrates the significant improvements of the model results on a real practical industrial application, which also validates the proposed model.
Reliability analysis of an automated pizza production line
Journal of Food Engineering, 2005
We present a statistical analysis of failure data of an automated pizza production line, covering a period of four years. The analysis includes the computation of descriptive statistics of the failure data, the identification of the most important failures, the computation of the parameters of the theoretical distributions that best fit the failure data, and the investigation of the existence of autocorrelations and cross correlations in the failure data. The analysis is meant to guide food product machine manufacturers and bread & bakery products manufactures improve the design and operation of their production lines. It can also be valuable to reliability analysts and manufacturing systems analysts, who wish to model and analyze real manufacturing systems.
Mathematics
With advanced manufacturing technology, organizations like to cut their operational cost and improve product quality, yet the importance of human labor is still alive in some manufacturing industries. The performance of human-based systems depends much on the skill of labor that varies person to person within available manpower. Much work has been done on human resource and management, however, allocation of manpower based on their skill yet not investigated. For this purpose, this study considered offline inspection system where inspection is performed by the human labor of varying skill levels. A multi-objective optimization model is proposed based on Time-Varying factors; inspection skill, operation time and learning behavior. Min-max goal programming technique was used to determine the efficient combination of inspectors of each skill level at different time intervals of a running order. The optimized results ensured the achievement of all objectives of inspection station: the c...
Daily counting of manufactured units sent for quality control: a bayesian approach
Pesquisa Operacional, 2013
This paper presents the statistical modeling for daily counting statistics of units that arrive for quality inspection at a food company. Different Poisson regression models were considered in order to analyze the data collected, with a Bayesian focus. The main objective was to forecast the daily average count based on co-variables such as days of the week. The analysis of co-variables is very often neglected by statistical packages that come with Discrete Event Simulation software. The discovery of the factors that influence these variations was essential to a more accurate modeling (the definition of simulation calendars) and enables industrial managers to make better decisions about the reallocation of people in the department, resulting in better planning of production capacity.
Model-based Inspection for the Control of Quality in Advanced Manufacturing Environments
2013
Manufacturing processes for markets that involve high levels of customization are inherently exposed to unpredictable and often inconsistent demands. The use of statistical methods for controlling quality in these environments is not suitable. The implementation of 100% inspection would guarantee high levels of quality but involves high inspection costs, whereas 0% inspection is associated with high throughputs without being able to guarantee the outgoing quality of products. This research used the Expected Value Formula to provide a model that determined whether an inspection station should be activated or not. The modeldecision depended on specified parameters such as the internal, external and appraisal costs as well as the significance of the inspected feature. The overall profits and Cost of Quality metric were used to analyse the system performance and compare the model-based inspection criteria to the 100% and 0% inspection strategies, using simulations performed in Labview. ...
Joint Determination of Production Quantity, Inspection Schedule, and Control Chart Design
IIE Transactions, 1994
In this paper, we study the simultaneous effects of both deteriorating product items and deteriorating production processes on economic production quantity, inspection schedules, and the economic design of control charts. Deterioration times for both product and process are assumed to follow arbitrary probability distributions. The product quality characteristic, however, is assumed to be normally distributed. Applications of the proposed model are demonstrated through illustrative examples.
Economic optimization of off-line inspection
IIE Transactions, 2000
In this paper we solve the problem of determining the optimal inspection/disposition policy for a ®nite batch of items produced by a machine that is subject to random breakdowns. In particular, we identify which units should be inspected and in which order so as to minimize costs. The operational implications of the optimal policy are analyzed with a selected set of numerical results. We place special emphasis on three dierent policies: the cost minimizing policy; the policy of perfect information, i.e., we insist on determining the quality of each unit; and the policy of zero-defects, i.e., we insist that all accepted units are known to conform to speci®cations, allowing the rejection of units of unknown quality. We also show how the optimal inspection/disposition policy is incorporated into the optimization of the batch size.