This study develops a postponement model for the multi-item replenishment decision featuring commonality, an overtime strategy, and product quality reassurance. A single machine is used to meet the steady demand for multiple products wherein product commonality exists among these end products. The proposed postponement model assumes that all pertinent common parts are fabricated in Stage 1 and the finished products are sequentially fabricated in Stage 2. Random nonconformance rates are associated with both fabrication stages, the repairable nonconforming common parts are separated from scrap, and reworking in each cycle helps ensure product quality for each completed batch. An overtime strategy is used to reduce the lengthy fabrication and rework times for common parts. Mathematical analyses and derivation allow us to obtain the total system costs. The optimization method helps find the optimal replenishment decision. We provide a numerical illustration to show (1) how our model works; (2) the individual impact of the system features (e.g., the overtime factor, commonality in terms of the common part completion rate and its relative value, and the issues pertaining to scrap/rework) on the optimal decision, utilization, and the total system cost; and (3) the collective influence of system features on the highlighted problem. This proposed decision-support model helps production managers achieve the operating goals of lowering total system expenses and cutting the length of the production cycle.

Production managers face the growing trend of rapid-response orders and inevitable production defects and failures; they must carefully measure these factors’ effects to minimize operating expenditures and operational disruption. Inspired by assisting producers decide the optimal runtime policy under these real situations, this work investigates the collective impact of rework, expedited-rate, external source, and machine failures on such a specific fabrication system. A partial outsourcing and expedited manufacturing rate are considered in the studied system to reduce the batch fabricating time. Additionally, defects rework and repair failure machines are implemented to retain the quality and avoid production disruption. Our research scheme consists of (1) developing a model for the mentioned manufacturing characteristics; and (2) analytical and optimization techniques for deciding the best batch runtime decision by minimizing the system’s overall expenses. Lastly, we provide numerical examples to demonstrate the model’s applicability and disclose important, in-depth characteristics that facilitate managerial decision-making.

Operating in today’s highly competitive global markets, transnational enterprises always seek to optimize internal vendor-buyer coordinated systems to ensure timeliness and quality deliveries, given the reality of unreliable machines and limited capacity. To facilitate accurate decision making to help organizations gain competitive advantages in such situations, this study explores an intra-supply-chain problem featuring a partial outsourcing batch fabrication plan, random scrap, Poisson-distributed breakdown rate, and multiple shipments of end-product. First, we build a model to characterize the problem clearly. Then, we carry out formulations, analyses, and derivations of the model to attain the problem’s cost function. We then use differential calculus and propose a specific algorithm to confirm the convexity of the obtained cost function and derive the optimal runtime. Finally, we offer a numerical illustration to demonstrate the result’s applicability for other business circumstances. Additional elements of the problem are then discussed, including the individual and combined influence of variations in scrap, outsourcing, breakdown, and shipping frequency. The features of an optimal operating policy and cost relevant parameters are now revealed to assist management with strategic planning and decision making in real-world intra-supply-chain environments.

When operating in highly competitive business environments, contemporary manufacturing firms must persistently find ways to fulfill timely orders with quality ensured merchandise, manage the unanticipated fabrication disruptions, and minimize total operating expenses. To address the aforementioned concerns, this study explores the optimal runtime decision for a manufacturing system featuring an expedited fabrication rate, random equipment failures, and scrap. Specifically, the proposed study considers an expedited rate that is linked to higher setup and unit costs. The fabrication process is subject to random failure and scrap rates. The failure instance follows a Poisson distribution, is repaired right away, and the fabrication of interrupted batch resumes when the equipment is restored. The defective goods are identified and scrapped. Mathematical modeling and optimization method are used to find the total system cost and the optimal runtime of the problem. The applicability and sensitivity analyses of research outcome are illustrated through a numerical example. Diverse critical information regarding the individual/joint impacts of variations in stochastic time-to-failure, expedited rate, and random scrap on the optimal runtime decision, total system expenses, different cost components, and machine utilization, can now be revealed to assist in in-depth problem analyses and decision makings.

This research constructs a mathematical scheme to explore replenishment-shipment decisions for a multiproduct producer-client coordinated finite production rate (FPR) model with the postponement, rework, and subcontracting plan. The considered multiple goods have a common component, and a batch FPR fabrication with postponement is planned to meet the annual multiproduct requirements. The first fabricating phase makes only the standard components needed for a batch and subcontracts a proportion of them (with additional cost) to expedite the process. In contrast, the second fabricating phase produces the finished multiple merchandise in sequence. The in-house rework processes with extra expense help retain the desirable quality. Each merchandise’s finished batch is transported to the clients in equal-sized numerous shipments. This study derives the optimal batch cycle length and transporting frequency by minimizing the overall fabricating-shipment expenses (including clients’ holding costs). This work offers a numerical example demonstrating various crucial system features influenced by the factors of subcontracting, postponement, rework, and transportation policies to facilitate managerial decision making in industries.

Transnational corporations, which operate in competitive global marketplaces, have to build the best possible intra-supply chain model for meeting, on time, clients’ need for multiple products with the requisite quality. Since fabrication capacity is always limited, the introduction of the external provider option can assist in leveling utilization, smoothing manufacturing schedules, eliminating overtime usage, and shortening the length of the fabrication cycle. Seeking to support intra-supply chain planning, this research aims to provide a concurrent decision on rotation cycle length and delivery frequency for a multi-item vendor-buyer incorporated type of intra-supply chain system with an external provider and rework. First, a model is built to represent this hybrid inventory replenishing problem. Then, renewal reward theory, mathematical derivation, and Hessian matrix equations are utilized to arrive at the expected total cost of the model, as well as the best policies for both cycle time and distribution. Last, the applicability and sensitivity analyses of our results are exhibited by a numerical demonstration. The insights obtained from this study about critical system-related information, such as the individual and joint impacts of the variation in outsourcing and reworking-related features on the system’s optimal operating policy and various performance parameters, will offer crucial help to the managerial functions of planning and decision making in firms using this realistic multi-item hybrid intra-supply chain system.

Facing stiff competition in worldwide markets, capability of meeting timely demands of multiproduct and satisfying customer’s desired product quality are essential to present-day manufacturers. Motivated by achieving the aforementioned goals, this research intends to find most economic common cycle length for a multiproduct finite production rate (FPR)-based inventory system, wherein, imperfect production process with expedited fabrication rate and random scrap is assumed. Extra setup and unit costs are associated with the adjusted rate, and imperfect products are screened and scrapped. A mathematical model is cautiously constructed to examine and resolve the problem. A numerical illustration is employed to exhibit the applicability of the proposed method. Except finding the most economic common cycle time for the problem, core contribution of this study also is associated with the individual and combined impact(s) of important factors to the problem, and hence, enabling management of manufacturing firms to make efficient/cost-effective decision and gain competitive advantages.

The study applies a postponement strategy to a multi-item fabrication-shipment decision making in a vendor-buyer coordinated environment with multi-delivery, quality reassurance, and overtime. To cope with the recent client demand trend asking for rapid response, quality, and diversified goods, today’s manufacturers require a multi-item production-shipping scheme to satisfy customers’ needs in cost-saving, quality, and timely matter. In our model, we first produce all needed mutual components and postpone manufacturing of finished goods in the second phase. To expedite mutual parts’ fabrication time, overtime is used. Product quality is reassured through screening the defeats and reworking repairable defectives in both fabrication phases. To decide the optimal fabrication-shipment policy, we build a math model and apply the cost minimization technique to the problem. Upon deriving the optimal policy, we utilize an example to demonstrate how our model works and its capability in exposing various previously inaccessible information to the problem. These detailed results can facilitate managerial decision-making and boost the performance of such a specific multi-item postponement fabrication-shipment system in cost-saving, product quality, and timely response.

With the intention of addressing product quality, machine reliability, and acceptable service level issues in real fabrication systems, this paper studies joint effects of stochastic breakdown, backorder of permissible shortage, rework, and scrap on the optimal stock replenishing policy. A decision model is developed to solve the problem, which consists of mathematical modeling, formulations, and optimization method in order to help analyze the problem, derive the system cost function, and find the optimal replenishment cycle length decision. Applicability of the research results are demonstrated by a numerical example. The proposed decision model enables production managers to not only determine the optimal stock replenishing policy, but also reveal individual impact and/or joint effects of stochastic breakdown, defective rate, backorder of allowable shortage, rework, and scrap on the replenishing decision. With such an in-depth study, diverse system characteristics become available for managerial decision-making.

Operating in today’s turbulent and competitive world marketplaces, manufacturers must find the best production scheme and delivery policy to meet timely client’s multiproduct requirements and minimize the total manufacturing-shipment expenses. This study proposes a two-stage delayed differentiation model for a multiproduct manufacturer-retailer coordinated supply chain featuring the adjustable-rate for making common parts and a multi-shipment policy for transporting finished goods. The aim is to help present-day manufacturers achieve their operational goals mentioned above. The mathematical techniques help us build a specific model to explicitly represent the problem and derive its overall operating expense. Then, the convexity of the total expense is verified by Hessian matrix equations. The differential calculus helps derive the cost-minimized fabrication-shipment decision. This study offers an example to demonstrate the applicability and capabilities of our proposed model numerically. The following crucial information has been made available to the managers to facilitate their operating decision makings: (1) the problem’s best fabrication-shipment policy; (2) the collective influence of various common part’s completion rates and values on the problem’s total expenses and optimal fabrication-shipment policy; (3) the impact of various adjustable-rates in stage one on utilization and stage one’s uptime; (4) the details of cost contributors to the problem; and (5) the collective impacts of critical features on the problem’s performance.