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      Quality control chart design under jidoka

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      Author(s)
      Berk, E.
      Toy, A. Ö.
      Date
      2009
      Source Title
      Naval Research Logistics
      Print ISSN
      0894-069X
      Publisher
      John Wiley & Sons, Inc.
      Volume
      56
      Issue
      5
      Pages
      465 - 477
      Language
      English
      Type
      Article
      Item Usage Stats
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      282
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      Abstract
      We consider design of control charts in the presence of machine stoppages that are exogenously imposed (as under jidoka practices). Each stoppage creates an opportunity for inspection/repair at reduced cost. We first model a single machine facing opportunities arriving according to a Poisson process, develop the expressions for its operating characteristics and construct the optimization problem for economic design of a control chart. We, then, consider the multiple machine setting where individual machine stoppages may create inspection/repair opportunities for other machines. We develop exact expressions for the cases when all machines are either opportunity-takers or not. On the basis of an approximation for the all-taker case, we then propose an approximate model for the mixed case. In a numerical study, we examine the opportunity taking behavior of machines in both single and multiple machine settings and the impact of such practices on the design of an X̄ - Q C chart. Our findings indicate that incorporating inspection/repair opportunities into QC chart design may provide considerable cost savings.
      Keywords
      Control chart design
      Jidoka process control
      Opportunistic inspection
      Statistical process control
      Approximate model
      C chart
      Control chart design
      Control charts
      Cost saving
      Economic design
      Jidoka process control
      Multiple machine
      Numerical studies
      Operating characteristics
      Opportunistic inspection
      Optimization problems
      Poisson process
      Quality control charts
      Reduced cost
      Single machines
      Flowcharting
      Machine design
      Poisson distribution
      Quality assurance
      Quality control
      Quality function deployment
      Surface treatment
      Total quality management
      Statistical process control
      Permalink
      http://hdl.handle.net/11693/22673
      Published Version (Please cite this version)
      http://dx.doi.org/10.1002/nav.20357
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      • Department of Management 579
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