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Generalising optimal mean setting for any number and combination of serial and parallel manufacturing operations

Generalising optimal mean setting for any number and combination of serial and parallel manufacturing operations
Generalising optimal mean setting for any number and combination of serial and parallel manufacturing operations
Consider a production system where products are continuously manufactured and their features inspected for conformance within specification limits. If features are produced above or below the specification limits, they are either subject to rework or the product scrapped. Optimal mean setting may be applied to adjust the manufacturing means to influence the amount of rework or scrap produced, maximising profit. Within the production system, manufacturing and then inspecting each feature in turn is termed serial production, whereas manufacturing multiple features before inspection is termed parallel production. This paper develops a generalised expression to optimise the mean values of each feature (optimal mean setting), where n number of features are produced in any combination of serial and parallel operations. Previous literature is restricted to considering two features in parallel. The production of multiple features in combinations of serial and parallel operations is not fully considered. The new generalised expression is validated by showing it is consistent with specific cases from past literature. The approach is then applied to a practical example of a gearbox shaft, considering the expected profit of eight possible manufacturing sequences, as well as the deviation of the manufactured means relative to the design intent. The generalised expression is widely applicable in component design and manufacturing planning where the process capability index (Cpk) of features is below one. The generalised expression also forms the basis for trade-offs between profitability and minimising deviations of manufactured means, which is the subject of further development.
0925-5273
Dodd, Christopher S.
07869879-f243-4352-b8f2-0919f2a5f4c8
Scanlan, James
7ad738f2-d732-423f-a322-31fa4695529d
Wiseall, Steve
aca297bd-610d-44d4-a77a-f00bb4753ce4
Dodd, Christopher S.
07869879-f243-4352-b8f2-0919f2a5f4c8
Scanlan, James
7ad738f2-d732-423f-a322-31fa4695529d
Wiseall, Steve
aca297bd-610d-44d4-a77a-f00bb4753ce4

Dodd, Christopher S., Scanlan, James and Wiseall, Steve (2016) Generalising optimal mean setting for any number and combination of serial and parallel manufacturing operations. International Journal of Production Economics. (doi:10.1016/j.ijpe.2016.02.009).

Record type: Article

Abstract

Consider a production system where products are continuously manufactured and their features inspected for conformance within specification limits. If features are produced above or below the specification limits, they are either subject to rework or the product scrapped. Optimal mean setting may be applied to adjust the manufacturing means to influence the amount of rework or scrap produced, maximising profit. Within the production system, manufacturing and then inspecting each feature in turn is termed serial production, whereas manufacturing multiple features before inspection is termed parallel production. This paper develops a generalised expression to optimise the mean values of each feature (optimal mean setting), where n number of features are produced in any combination of serial and parallel operations. Previous literature is restricted to considering two features in parallel. The production of multiple features in combinations of serial and parallel operations is not fully considered. The new generalised expression is validated by showing it is consistent with specific cases from past literature. The approach is then applied to a practical example of a gearbox shaft, considering the expected profit of eight possible manufacturing sequences, as well as the deviation of the manufactured means relative to the design intent. The generalised expression is widely applicable in component design and manufacturing planning where the process capability index (Cpk) of features is below one. The generalised expression also forms the basis for trade-offs between profitability and minimising deviations of manufactured means, which is the subject of further development.

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Accepted/In Press date: 10 February 2016
e-pub ahead of print date: 26 February 2016
Additional Information: This paper develops a generalised approach to optimal mean setting where n number of features are produced in any combination of serial and parallel operations. Manufacturing and then inspecting each feature in turn is termed serial production, whereas manufacturing multiple features before inspection is termed parallel production. Previous literature is restricted to considering two features in parallel and the production of multiple features in combinations of serial and parallel operations is not fully considered. The new generalised expression presented in this paper is consistent with (but advances) the Markovian modelling techniques developed in past literature. Some inaccuracies relating to two-feature parallel production systems in the literature are also resolved. The practical benefit of this new generalised expression is used to find the most profitable manufacturing sequence as well as the optimal means for the production of a speed reducer gearbox shaft.
Organisations: Computational Engineering & Design Group

Identifiers

Local EPrints ID: 381398
URI: http://eprints.soton.ac.uk/id/eprint/381398
ISSN: 0925-5273
PURE UUID: a68b25d4-00a2-4ff1-8d1d-6be7367525c1

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Date deposited: 06 Oct 2015 13:14
Last modified: 13 Jul 2020 16:34

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Contributors

Author: Christopher S. Dodd
Author: James Scanlan
Author: Steve Wiseall

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