臺灣博碩士論文加值系統

一般生產過程中瑕疵品的產生通常無法避免，產生瑕疵品的原因有很多，從投入的原料品質、老舊的生產設備、操作人員的熟練度等等，皆會直接影響到產品產出的品質進而影響整體生產成本。尤其近年隨著經濟快速發展，全球對原物料需求大增導致原物料短缺以及價格上漲，讓企業的生產營運成本大增。因此，針對損耗性商品之非完美生產系統，製造商如何規劃符合經濟效益的生產系統及存貨模式來滿足需求並落實精實生產、有效管理存貨、降低生產成本提高利潤空間，將是企業永續發展的重要關鍵因素。
本研究針對相關文獻資料進行探討，並發展出一套單階非完美生產系統進行檢驗、重工、允許缺貨補貨的生產存貨模式及流程。假設及考量商品具有損耗之特性，允許缺貨問題發生，透過檢驗將分類出來的瑕疵品進行重工，當缺貨達到一定水準時則開始新的生產進行缺貨補貨並將缺貨全數補足。同時，製造商針對商品損耗率及生產瑕疵率問題進行保存技術及品質改善等投資，有效降低生產總成本、提高生產良率及生產存貨量以滿足需求。透過情境模擬建構數學模型，利用最佳化方法求得最佳生產存貨模式及最小生產系統總成本。最後經由數值範例與敏感度分析了解各個參數對本模式的影響，並做出結論、建議以及未來研究方向。

The generation of imperfect quality product during the manufacturing process is inevitable, the factors made up with imperfect raw materials, insufficient manufacturing processes, poor production devices, inadequate qualification of employees…etc., are directly impact the quality of finished products and increase the overall cost of whole production system. Particularly the global market has witnessed shortage of raw materials with fluctuating costs that makes situation worsened to the manufacturing sectors in recent years. In response to these concerns, manufactures are keen to build up the cost-effective production system with a robust inventory model, as how to implement lean production, structure an effective inventory management, and squeeze the production overall cost for a good margin of profit from imperfect production systems are critical elements for enterprises.
In this study, a single stage of imperfect production system proceeds with inspection, rework, allowable backorder, and backorder replenishment rate for a deteriorating item are considered and set to simulate as a real situation derived a heuristic algorithm model for an optimal inventory when shortage caused by deterioration can be completely replenished. Meanwhile, the preservation technology and quality improvement investments are simultaneously incorporated to minimize the overall cost of whole production system improving the deterioration and defective rates effectively by rising up the production yields and shortening the lead time with an optimal solution to satisfy market demands is the objective of this research. Numerical examples and sensitivity analyses are given to validate the results of inventory system. The study ends with managerial implications for a manufacturing firm towards decision-making for determining optimal production policies for imperfect production systems and directions for future research.

摘要 I
ABSTRACT II
目錄 III
表目錄 V
第一章 緒論 1
1.1 研究背景與動機 1
1.2 研究目的與範圍 3
1.3 研究流程 4
2.1 損耗性產品存貨相關文獻 6
2.2 非完美生產存貨系統之相關文獻 8
2.2 非完美生產存貨系統之相關文獻 9
2.3 產品檢驗 11
2.4 瑕疵品重工 14
2.5 缺貨水準及補貨政策 16
2.6 保存技術 18
2.7 品質改善 19
2.8 研究方法 21
第三章 損耗性商品非完美生產系統存貨模式 22
3.1問題定義與描述 22
3.2 研究假設 25
3.3 參數符號說明與定義 26
3.4 存貨模式建構與推導 27
3.4.1 參數模型 30
3.4.2 存貨週期各項成本 38
3.5 數值範例 41
3.6 敏感度分析 45
3.6.1 正常生產期間時間長度之敏感度彙整 46
3.6.2 單位時間總成本之敏感度彙整 51
第四章 導入保存技術及品質改善之存貨模式 55
4.1 問題定義與描述 55
4.2 研究假設 58
4.3 參數符號說明與定義 59
4.4 存貨模式建構與推導 60
4.5 數值範例 66
4.6 敏感度分析 69
4.6.1 正常生產期間時間長度之敏感度彙整 70
4.6.2 單位時間總成本之敏感度彙整 75
第五章 結論、貢獻與未來發展 79
5.1 結論 79
5.2 貢獻 83
5.3 未來研究方向 84
參考文獻 85

中文文獻
[1] 鐘志芳(1997)，損耗性產品在原料不同訂購策略下之整合生產存貨模式， 中原大學碩士論文
[2] 李旭華、杜振輝、李國樑、劉玉珠(2002)，「不完美生產系統之品質改善及
訓練與製造時間之成本效益模式」，中華民國品質學會第38屆年會暨第8屆全
國品質管理研討會，台北市
[3] 魏凡峯(2002)，逆物流對供應鍊體系成本與時間之影響，國立成功大學工業
管理研究所碩士論文
[4] 黃揚勝(2009)，損耗性商品在協同定價與延遲付款之存貨模式，中原大學工
業與系統工程學系碩士論文
英文文獻
[1] Affisco, J.F., Paknejad, M.J., Nasri, F., 2002. Quality Improvement and setup reduction in the joint economic log size model. European Journal of Operational Research, Vol.142, pp.497-508.

[2] Aggarwal, S.P., and Jaggi, C.K., 1995. Ordering policies of deteriorating items under permissible delay in payments. Journal of the Operational Research Society, Vol. 46, pp.658-662.

[3] Alfares, H., 1999. A simulation model for determining inspection policy. Computers and Industrial Engineering,Vol. 36, pp.685-696.

[4] Biswas, P., Sarker, B.R., 2008. Optimal batch quantity models for a lean production syetem with in-cycle rework and scrap. International Journal of Production Research, Vol.46, No.23, pp.6585-6610.
[5] Cardenas-Barron, L.E., 2009. Economic production quantity with rework process at a single-stage manufacturing system with planned backorders. Computers and Industrial Engineering, Vol.57, pp.1105-1113.
[6] Chen, F.Y., Krass, D., 2001. Inventory models with minimal service level constraints. European Journal of Operational Research , Vol.134, pp.120-140.
[7] Chiu, Y.S.P., 2003. Determining the optimal lot size for the finite production model with random defective rate, the rework process, and backlogging. Engineering Optimization , Vol.35, No.4, pp.427-437.
[8] Chiu, S.W., Gong, D.C., Wee, H.M., 2004. The effects of random defective rate and the imperfect rework process on the economic production quantity model. Japan. Journal of Industrial and Applied Mathematics, Vol.21, pp.375-389.
[9] Chiu, Y.S.P., Chiu, S.W., Lin, H.D., 2006. Solving and EPQ model with rework and service level constraint. Mathematical and Computational Applications, Vol.11, No.1, pp.75-84.
[10] Chern, M.S., Yang, H.L., Teng, J.T., and Sotiris Papachristos, 2008. Partial backlogging inventory lot-size models for deteriorating items with fluctuating demand under inflation. European Journal of Operational Research, Vol.191, pp.127-141.
[11] Chiu, Y.S.P., Chen, K.K., Cheng, F.T., Wu, M.F., 2010. Optimization of the finite production rate model with scrap, rework, and stochastic machine breakdown. Computers and Mathematics with Applications, Vol.59, pp.919-932.
[12] Chiu, S.W., 2010. Robust planning in optimization for production system subject to random machine breakdown and failure in rework. Computers & Operations research, Vol.37, pp.899-908.
[13] Chung, K.J., Hou, K.L., 2003. An optimal production run time with imperfect production processes and allowable shortages. Computer and Operation Research, Vol. 30, pp. 483-490.
[14] Dye, C.Y., 2007. Joint pricing and ordering policy for a deteriorating inventory with partial backlogging. Omega, Vol.35, pp.184-189.
[15] Dye, C.Y., Ouyang, L.Y., and Hsieh, T.P., 2007. Inventory and pricing strategies for deteriorating items with shortages: A discounted cash flow approach. Computers & Industrial Engineering, Vol.52, pp.29–40.
[16] Gupta, T., Chakrabarty, S., 1984. Looping in a multi-stage production system. International Journal of Production Research, Vol,22, No.2, pp.299-311.
[17] Giri, B.C., Chakrabarty, T., and Chaudhuri, K.S., 2000. A note on a lot sizing heuristic for deteriorating items withtime-varying demands and shortages. Computers & Operations Research, Vol.27, pp.495-505.
[18] Hopp, W.J., Spearman, M.L., Zhang, R.O., 1997. Easily implementable inventory control policies. Operations Research, Vol.45, No.3, pp.327-340.
[19] Hong, S.H., Kim, S.B., Kwon, H.M., Lee, M.K.,1998. Economic design of screening procedures when the rejected items are reprocessed. European Journal of Operations Research, Vol.108,No.1, pp.65-73.
[20] Hou, K.L., 2006. An inventory model for deteriorating items with stock-dependent consumption rate and shortages under inflation and time discounting. European Journal of Operational Research, Vol.168, pp.463-474.
[21] Hsu, P.H., Wee, H.M., and Teng, H.M., 2007. Optimal ordering decision for deteriorating items with expiration date and uncertain lead time. Computers & Industrial Engineering, Vol.52, pp.448-458.
[22] Hsu, P.H., Wee, H.M., and Teng, H.M., 2010. Preservation technology investment for deteriorating inventory. International Journal Production Economics, Vol.124, pp.388-394.
[23] Hsieh, T.P., Dye, C.Y., 2012. An optimal replenishment policy for deteriorating items with effective investment in preservation technology. European Journal of Operational Research, Vol.218, pp.106-112.
[24] Hsieh, T.P., Dye, C.Y., 2013. A production-inventory model incorporatingnthe effect of preservation technology investment when demand is fluctuating with time. Journal of Computational and Applied Mathematics, Vol.239, pp.25-36.
[25] Inderfurth, K., Lindner, G., Rachaniotis, N.P., 2005. Lot sizing in a production system with rework and product deterioration. International Journal of Production Research, Vol.43, No.7, pp.1355-1374.
[26] Jamal, A.M.M., Sarker, B.R., and Wang, S., 1997. An ordering policy for deteriorating items with allowable shortages and permissible delay in payment. Journal of the Operational Research Society, Vol.48, pp.826-833.
[27] Jamal, A.M.M., Sarker, B.R, Mondal, S., 2004. Optimal manufacturing batch size with rework process at a single-stage production system. Computer & Industrial Engineering , Vol.47, pp.77-89.
[28] Jie Li, K., Jo, M., Toshisugu, O., Timothy Van, V., 2008. Inventory and investment in setup and quality operations under return on investment maximization. European Journal of Operational Research, Vol.185, No.2, pp.593-605.
[29] Jonas C.P.Yu, 2005. Optimal ordering policy for a deteriorating item with imperfect quality and partial backordering. Journal of the Chinese Institute of Industrial Engineers, Vol.22, pp.509-529.
[30] Lee, H.L., 1992. Lot sizing to reduce capacity utilization in a production process with defective items, process corrections, and rework. Management Science, Vol.38, No.9, pp.1314-1328.
[31] Lin, L.C., Hou, K.L., 2005. An inventory system with investment to reduce yield variability and setup cost. Journal of the Operational Research Society, Vol.56, No.8, pp.67-74.
[32] Liu, J.J., Yang, P., 1996. Optimal lot-sizing in an imperfect production system with homogeneous reworkable jobs. European Journal of Operational Research 91, 517-527.
[33]Misra, R.B., 1975. Optimum production lot size model for a system with deteriorating inventory. International Journal of Production Resarch 15, Vol.13, pp.495-505.
[34] Ouyang, L.Y., Chen, C.K., Chang, H.C., 2002. Quality Improvement, setup cost, and lead-time reductions in lot size reorder point models with an imperfect production process. Computer & Operations Research, Vol.29, pp.1701-1717.
[35] Ouyang, L.Y., Teng, J.T., Goyal, S.K., and Yang, C.T., 2009. An economic order quantity model for deteriorating items with partially permissible delay in payments linked to order quantity. European Journal of Operational Research, Vol.194, pp.418–431.
[36] Ojha, D., Sarker, B.R., Biswas, P., 2007. An optimal batch size for an imperfect production system with quality assurance and rework. International Journal of Production Research, Vol. 45, No.14, pp. 3191-3214.
[37] Rebello, R., Agnetis, A., Mirchandani, P.B., 1995. Specialized inspection problem in serial production systems. European Journal of Operational Research,Vol.80, pp.277-296.
[38]Rosenblatt, M.J., Lee, H.L., 1986. Economic production cycles with imperfect production process. IIE Transaction, Vol.18, No.1, pp. 48-55.
[39]Raafat, F., 1991. Survey of literature on continuously deteriorating inventory models. Journal of Operational Research Society, Vol.42, No.1, pp.27-37.
[40] Roy, A., Kar, S., and Maiti, M., 2008. A deteriorating multi-item inventory model with fuzzy costs and resources based on two different defuzzification techniques. Applied Mathematical Modellin, Vol.32, pp.208-223.
[41] Salameh, M.K., Jaber, M.Y., 2000. Economic production quantity model for items with imperfect quality. International. Journal of Production Economics, Vol. 64, pp.59-64.
[42] Sana, S., 2010. An economic production lot size in an imperfect production system. European Journal of Operations Research, Vol. 201, pp.158-170.
[43] Sarker, B.R., Jamal, A.A.M., Model, S., 2008. Optimal batch sizing in a multi-stage production system with rework consideration. European Journal of Operational Research, Vol.184, No.3, pp.915-929.
[44] Sarker, B., Moon, I., 2011. An EPQ model with inflation in an imperfect production system. Applied Mathematics and Computation, Vol. 217, pp. 6157-6167.
[45]Schneider, H., Ringuest, J.L., 1990. Power approximation for computing (s,S) policies using service level. Management Science, Vol.36, No.7, pp.822-834.
[46] Taleizadeh, A.A., Niaki, S.T.A., Najafi, A.A., 2010. Multiproduct single-machine production system with stochastic scrapped production rate, partial backordering and service level constraint. Journal of Computational and Applied Mathematics, Vol. 233, pp.1834-1849.
[47] Teunter, R.H., Flapper, S.D.P., 2001. Logistic planning and control of reworking perishable defectives. Econmetric Institute EI2001-36.
[48]Thevenaz, C. and Resodihardjo, S.L., 2010. All the best laid plans-conditions impeding proper emergency response. International Journal of Production Economics, Vol.126, pp.7-21.
[49] Wang, C.H., Meng, F.C., 2009. Optimal lot size and offline inspection policy. Computer and Mathematics with Applications, Vol.58, pp.1921-1929.
[50]Wein, A.S.,1992. Random yield, rework and scrap in a multi-stage batch manufacturing environment. Operation Research, Vol. 40, No.3, pp.551-563.
[51] Wee, H.M., 1993. Economic production lot size model for deteriorating items with partial back-ordering. Computers and Industrial Engineering, Vol.24, pp.449-458.
[52] Wee, H.M., 1998. Optimal Buyer-seller Discount Pricing and Ordering Policy for Deteriorating Items. The Engineering Economist, Vol.643, No.2, pp.151-168.
[53] Wee, H.M., and Law, S.T., 2001. Replenishment and pricing policy for deteriorating items taking into account the time-value of money. International Journal of Production Economics, Vol.71, pp.213-220.
[54] Wee, H.M., Yu Jonas, and Chen, M.C., 2007. Optimal inventory model for items with imperfect quality and shortage backordering. Omega 35, pp.7-11.
[55] Yang, H.L., 2005. A comparison among various partial backlogging inventory lot-size models for deteriorating items on the basis of maximum profit. International Journal of Production Economics, Vol.96, pp.119-128.
[56] Yang, H.L., 2004. Two-warehouse inventory models for deteriorating items with shortages under inflation. European Journal of Operational Research, Vol.157, pp.344-356.
[57] Yu, H.F., Yu, W.C., 2007. An optimal mixed policy of inspection and burn-in and the optimal production quantity. International Journal of Production Economics, Vol.105, No.2, pp.483-491.