Two non-linear programming models for the multi-stage multi-cycle smart production system with autonomation and remanufacturing in same and different cycles to reduce wastes

Abstract

Multi-stage production systems produce a severe amount of defective items as a result of an irregular quota of defectiveness. It is very important to remanufacture those imperfect pieces that are wasted and try to keep the model as reality close as possible. Two different models are developed in this study: a smart production system with numerous stages and with only one cycle and a smart production system with numerous stages and numerous cycles. The essential objective of this study is to scale down the overall waste and lower the final total cost in both models at the same time by optimizing the planned batch size, investments in each stage, and the production rate based on the demand. The remanufacturing of the defective products occurs in two ways. While the remanufacturing process in the smart multi-stage production system with a single cycle occurs within the cycle, the reworking in the case of a smart multi-stage production system with numerous cycles occurs in different cycles. Numerical examples are conducted and compared to illustrate the model quantitatively. It is found that in both scenarios of both models, the total cost is minimized.