Determining the optimal run time for EPQ model with scrap, rework, and stochastic breakdowns

This paper is concerned with determination of optimal run time for an economic production quantity (EPQ) model with scrap, rework, and stochastic machine breakdowns. In real life manufacturing systems, generation of defective items and random breakdown of production equipment are inevitable. In this study, a portion of the defective items is considered to be scrap, while the other is assumed to be repairable. Total production-inventory cost functions are derived respectively for both EPQ models with breakdown (no-resumption policy is adopted) and without breakdown taking place. These cost functions are integrated and the renewal reward theorem is used to cope with the variable cycle length. Theorems on conditional convexity of the integrated overall costs and bounds of the production run time are proposed and proved. We conclude that the optimal run time falls within the range of bounds and it can be pinpointed by the use of the bisection method based on the intermediate value theorem. Numerical example is provided to demonstrate its practical usages.