Manufacturing firms operating in today’s competitive global markets must continuously find the appropriate manufacturing scheme and strategies to effectively meet customer needs for various types of quality of merchandise under the constraints of short order lead-time and limited in-house capacity. Inspired by the offering of a decision-making model to aid smooth manufacturers’ operations, this study builds an analytical model to expose the influence of the outsourcing of common parts, postponement policies, overtime options, and random scrapped items on the optimal replenishment decision and various crucial system performance indices of the multiproduct problem. A two-stage fabrication scheme is presented to handle the products’ commonality and the uptime-reduced strategies to satisfy the short amount of time before the due dates of customers’ orders. A screening process helps identify and remove faulty items to ensure the finished lot’s anticipated quality. Mathematical derivation assists us in finding the manufacturing relevant total cost function. The differential calculus helps optimize the cost function and determine the optimal stock-replenishing rotation cycle policy. Lastly, a simulated numerical illustration helps validate our research result’s applicability and demonstrate the model’s capability to disclose the crucial managerial insights and facilitate manufacturing-relevant decision making.

This paper discusses an integrated model of batch production and maintenance scheduling on flow shop with two deteriorating machines producing single item to be delivered at a due date. The model describes the trade-off between production and maintenance costs as the production run length increases on two machines. The objective function of the model is to minimize the total cost consisting of in process and completed part inventory costs, setup costs, preventive & corrective maintenance costs and rework costs on two machines. The step-wise optimization algorithm is developed to solve a mixed integer quadratic programming. Comparison with the practice and the model sensitivity analysis are demonstrated to clarify how the algorithm works.

This paper discusses an integrated model of batch production and maintenance scheduling on a deteriorating machine producing multiple items to be delivered at a common due date. The model describes the trade-off between total inventory cost and maintenance cost as the increase of production run length. The production run length is a time bucket between two consecutive preventive maintenance activities. The objective function of the model is to minimize total cost consisting of in process and completed part inventory costs, setup cost, preventive and corrective maintenance costs and rework cost. The problem is to determine the optimal production run length and to schedule the batches obtained from determining the production run length in order to minimize total cost.

This paper presents an analytical technique to determine the optimum number of cards to control material release in a CONWIP system. The work focuses on the card setting problem for a flow-shop system characterised by the presence of a batch processing machine (e.g. a kiln for long heat treatment). To control production, two different static approaches are developed: the first one is used when the bottleneck coincides with the batch processing machine and the second one is proposed when the bottleneck is another machine of the flow shop. In both contexts, by means of the appropriate model, one can optimize the performance of the flow-shop by maximizing the throughput and keeping the work in process at a minimum level. Numerical examples are also included in the paper to confirm the validity of the models and to demonstrate their practical utility.