Optimal production lot sizing for an imperfect manufacturing system with machine breakdown and emergency maintenance policy

Abstract

Purpose

The purpose of this paper is to study a production lot sizing problem with consideration of imperfect manufacturing and emergency maintenance policy, providing managerial implication for practitioners.

Design/methodology/approach

In this study, the authors introduce two models, where in Model I, shortages are not allowed and repair times are negligible. In Model II, shortages are allowed and are partially backlogged, and repair times are assumed to be exponentially distributed, algorithm is developed to solve the models, numerical examples were demonstrated the applications.

Findings

Results show that in the Model I, demand rate is the most significant parameter affecting the average expected cost, whereas the time needed to breakdown after machine shift is the most significant factor affecting the production lot size. Therefore, reduction in the time needed to breakdown after machine shift would be helpful for determining an appropriate production lot size in Model I. In Model II, repair time parameter is the most significant factor affecting the average expected cost. Reducing the value of machine shift parameter would be helpful for determining an adequate production lot size and reducing decision risk.

Practical implications

This paper can provide important reference value for practitioners with managerial implication of how to effectively maintain equipment, i.e. how to make product lot size considering the influence of the maintenance policy.

Originality/value

From the aspect of academia, this paper provides a solution to the optimal production lot sizing decision for an imperfect manufacturing system with consideration of machine breakdown and emergency maintenance, which is a supplement to imperfect EMQ model.

Citation

Lai, X., Chen, Z. and Sarker, B.R. (2020), "Optimal production lot sizing for an imperfect manufacturing system with machine breakdown and emergency maintenance policy", Kybernetes, Vol. 49 No. 5, pp. 1533-1560. https://doi.org/10.1108/K-12-2018-0687