Abstract
Process quality planning should establish a Quality Control Plan (QCP) to achieve the desired quality level with minimum Cost of Quality (CoQ). This plan establishes the critical quality variables, control stations in the process, and control method at each control station. The purpose of this study is to, through a simulation approach, determine a QCP for a manufacturing process, which minimizes the CoQ. The inputs to the simulation model are inspection and repair/replace costs, proportion of defectives at process output, type I and Type II inspection errors, alternative control methods (no control or 100% inspection), and the cost of delivering defective units to the customer. The proposed model was developed in Simulation Modelling Based on Intelligent Objects (SIMIO) software to estimate the total CoQ and number of compliant units delivered. This model allows to determine the CoQ of the alternative scenarios and to define a QCP that minimizes the total CoQ. An illustrative example based on a manufacturing process demonstrates the applicability of this model, and the results indicate that the best QCP, amongst defined alternatives, may vary when the model parameters are updated. As future research directions, the simulation models could be relevant when defining digital twins of manufacturing processes and models’ results can support process improvements.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Rezaei-Malek, M., Mohammadi, M., Dantan, J.Y., Siadat, A.R.: A review on optimisation of part quality inspection planning in a multi-stage manufacturing system. Int. J. Prod. Res. 57(15–16), 4880–4897 (2019)
Haiping, Z., Cong, Z., Yuhao, D.: Optimisation design of attribute control charts for multi-station manufacturing system subjected to quality shifts. Int. J. Prod. Res. 54, 1804–1821 (2016)
Sousa, S., Nunes, E., Lopes, I.: Measuring and managing operational risk in industrial processes. FME Trans. 43, 295–302 (2015)
Sousa, S., Nunes, E.: Framework to determine the quality cost and risk of alternative control plans in uncertain contexts. Int. J. Ind. Eng.: Theory Appl. 27(5), 747–759 (2020)
Van Volsem, S., Dullaert, W., Van Landeghem, H.: An evolutionary algorithm and discrete event simulation for optimizing inspection strategies for multi-stage processes. Eur. J. Oper. Res. 179, 621–633 (2007)
Filz, A., Herrmann, C., Thiede, S.: Simulation-based assessment of quality inspection strategies on manufacturing systems. Procedia CIRP 93, 777–782 (2020)
Zhu, H., Zhang, C., Deng, Y.: Optimisation design of attribute control charts for multi-station manufacturing system subjected to quality shifts. Int. J. Prod. Res. 54, 1804–1821 (2016)
Ali, S., Pievatolo, A., Göb, R.: An overview of control charts for high-quality processes. Qual. Reliab. Eng. Int. 32, 2171–2189 (2016)
Glock, C.H., Grosse, E.H., Ries, J.M.: The lot sizing problem: a tertiary study. Int. J. Prod. Econ. 155, 39–51 (2014)
Psomas, E., Dimitrantzou, C., Vouzas, F., Bouranta, N.: Cost of quality measurement in food manufacturing companies: the Greek case. Int. J. Product. Perform. Manag. 67, 1882–1900 (2018)
Ayach, L., Anouar, A., Bouzziri, M.: Quality cost management in Moroccan industrial companies: empirical study. J. Ind. Eng. Manag. 12, 97–114 (2019)
Sarkar, B., Saren, S.: Product inspection policy for an imperfect production system with inspection errors and warranty cost. Eur. J. Oper. Res. 248(1), 263–271 (2016)
Maier, J., Eckert, C., Clarkson, P.: Experimental investigation of the implications of model granularity for design process simulation. J. Mech. Des. 141(7), 071–101 (2019)
Yoo, S.H., Kim, D., Park, M.S.: Lot sizing and quality investment with quality cost analyses for imperfect production and inspection processes with commercial return. Int. J. Prod. Econ. 140(2), 922–933 (2012)
Pires, A., Novas, J., Saraiva, M., Coelho, A.: How companies use the information about quality-related costs. Total. Qual. Manag. Bus. Excell. 28(5–6), 501–521 (2017)
Sousa, S., Rodrigues, N., Nunes, E.: Evolution of process capability in a manufacturing process. J. Manag. Anal. 5(2), 95–115 (2018)
Sousa, S., Nunes, E.: Inspection and repair cost modeling granularity: a pragmatic approach. In: International Conference on Decision Aid Sciences and Application, DASA 2021, pp. 567–572 (2021)
Dias, L., Nunes, E., Sousa, S.: Quality cost of 100% inspection on manufacturing processes: advantages of using a simulation approach. In: Lecture Notes in Mechanical Engineering IEEE International Conference on Industrial Engineering and Engineering Management (IEEM), Malaysia, pp. 1144–1148 (2022)
Dimitrantzou, C., Psomas, E., Vouzas, F.: Future research avenues of cost of quality: a systematic literature review. TQM J. 32, 1599–1622 (2020)
Acknowledgment
This work has been supported by FCT – Fundação para a Ciência e Tecnologia within the R&D Units Project Scope: UIDB/00319/2020.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2024 The Author(s), under exclusive license to Springer Nature Switzerland AG
About this paper
Cite this paper
Sousa, S.D., Dias, L.S., Nunes, E.P. (2024). Assessment of Alternative Quality Control Plans in Dynamic Contexts: A Simulation Approach. In: Silva, F.J.G., Ferreira, L.P., Sá, J.C., Pereira, M.T., Pinto, C.M.A. (eds) Flexible Automation and Intelligent Manufacturing: Establishing Bridges for More Sustainable Manufacturing Systems. FAIM 2023. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-031-38165-2_52
Download citation
DOI: https://doi.org/10.1007/978-3-031-38165-2_52
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-031-38164-5
Online ISBN: 978-3-031-38165-2
eBook Packages: EngineeringEngineering (R0)