A mathematical model on EPQ for stochastic demand in an imperfect production system

In the paper, we develop an EPQ (economic production quantity) inventory model to determine the optimal buffer inventory for stochastic demand in the market during preventive maintenance or repair of a manufacturing facility with an EPQ (economic production quantity) model in an imperfect production system. Preventive maintenance, an essential element of the just-in-time structure, may cause shortage which is reduced by buffer inventory. The products are sold with the free minimal repair warranty (FRW) policy. The production system may undergo out-of-control state from in-control state, after a certain time that follows a probability density function. The defective (non-conforming) items in in-control or out-of-control state are reworked at a cost just after the regular production time. Finally, an expected cost function regarding the inventory cost, unit production cost, preventive maintenance cost and shortage cost is minimized analytically. We develop another case where the buffer inventory as well as the production rate are decision variables and the expected unit cost considering the above cost functions is optimized also. The numerical examples are provided to illustrate the behaviour and application of the model. Sensitivity analysis of the model with respect to key parameters of the system is carried out. (c) 2012 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.