Optimization of rework policy and length of defective pipes in a continuous metal pipe manufacturing system

Document Type

Conference Proceeding

Publication Date

1-1-2017

Abstract

In a continuous metal pipe production system, various type of production defects are found to occur. In general, the defects occur randomly following Poisson distributions. The defective spots can be reworked or the defective portions can be scrapped based on their relevant cost. However, these two alternatives add extra costs to production. Besides these, some rework operations can be done on-line or at a separate off-line rework station. Another way to deal with these defects, is to cut off the defective portion yielding into small substandard pieces. This option reduces scrapping cost but adds extra cutting cost and loses productive time. The objective of this research is to find the best way to deal with these alternative options. A non-linear profit function is developed in terms of different cost parameters and desired length of standard and substandard pipes. The alternative decisions are indicated by some binary integer variables. This profit function and some relevant constraints form an integer non-linear programming (INLP) problem which is solved optimally. For a single type of defect the INLP problem is transformed into a mixed integer linear programming problem. The model successfully deals with the welding or extrusion defects in many continuous pipe production system.

Publication Source (Journal or Book title)

67th Annual Conference and Expo of the Institute of Industrial Engineers 2017

First Page

127

Last Page

132

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