考慮重工模式之最佳化JIT生產與運送批量決策

A research for an optimal JIT production and delivery lot size with rework

張清陽(Ching-Yang Chang)

指導教授 ： 邱裕方

中原大學/工學院/工業工程研究所/碩士(2006年)

https://doi.org/10.6840/cycu200600384

摘要

許多學者探討JIT採購與生產環境下的最佳經濟批量，也考慮到整合買方與賣方的總成本的模式，但是同時考慮到重工模式的文獻卻不多見，大部分關於最佳批量的研究所發展出的存貨模型都會假設條件為理想的情況，不過在現實生產過程中必定會有不良品的產生，製造商通常也具備重工的能力，因此不良品產生後將再次進入製程加工而成為完成品，一般存貨模式的生產率並沒有考慮不良率的存在，也甚至只是把不良率當成報廢，而將原生產率扣除不良率當作實際生產率，並沒有考慮到製造商重工的能力。因此本研究希望考慮生產的不良品率，並同時整合製造商重工的能力用以建立更符合實際生產情況的製造商的存貨模型。
另一方面，過去的研究只著重在一次訂購多次運送的JIT採購，與僅生產必要批量的JIT生產這兩項特徵，卻忽略精實生產環境下會造成設置成本降低的影響，在精實生產的環境下，不斷改善的生產環境會使設置成本持續的降低，也同時影響最佳生產批量的決定，因此本研究提出重新計算最佳生產以及運送批量的方法。綜合以上兩個問題，本研究模式在整合買方與賣方的JIT生產與運送模式加入重工問題，並且提出精實生產導致設置成本變動的概念，以建構本研究模式找出最佳化JIT運送與生產批量。

關鍵字

存貨模式 ； JIT ； 精實生產 ； 重工

並列摘要

Many researchers investigate about optimal lot size with JIT purchase and production. But they never consider rework problem. Most research inventory model with perfect assumption. Actually, in an imperfect manufacturing process, the defective items are produced with finished goods. Rework process is necessary to convert those defectives into finished goods. In this research, the inventory model consider the failure rate to conform the real production environment.

Prior researches consider optimal lot size model with JIT manufacturing and JIT purchasing. But they never consider the lean production. The successful lean production is through the various efforts and continuous improvements that make the setup cost reduce continuously. The reduction of setup cost result in the change of optimal lot-size. Therefore, this research considers the effect of lean production to obtain the production and delivery lot-size decisions with the minimum total cost in the JIT supply chain.

並列關鍵字

JIT ； Rework ； Lean production ； Iinventory model

參考文獻

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Agnihothri, S. R. ,and Kenett, R. S., “The impact of defects on a process with rework”, European journal of operational research, 80(2), pp.308-327,1995

Agnihothri, S. R. ,and Kenett, R. S., “Integrated production-inventory models for imperfect production processes under inspection schedules”, Computers and Industrial Engineering, 44(4), pp.633-650 ,2003.

Jamal A.M.M., Bhaba R. Sarker, and Sanjay Mondal, “Optimal manufacturing batch size with rework process at a single-stage production system” Computers & Industrial Engineering, 47, pp.77–89 ,2004.