A dynamic programming model for designing a quality control plan in a manufacturing process

Abstract

This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/) Process quality planning should establish the quality control plan to achieve the desired quality level with the minimum quality cost (appraisal and failure costs) for the final product. This plan sets out the critical quality variables, the control stations in the process, and the control method at each control station. The quality costs associated with quality control and defective products can be greater than or less than ideal regarding the required quality level. The purpose of this paper is to provide a stochastic dynamic programming model for designing the quality control plan in a manufacturing process, which allows obtaining the desired level of control with the lowest cost. Inputs to the model are, in particular, control stations in the process, levels of quality, control methodologies (no control, statistical process control, 100% inspection), probabilities of changing the quality level and quality costs. The output of this model is the quality control plan that satisfies the desired level of quality at the lowest cost. This plan establishes the control stations, the methodology used in each control station, the desired quality level for the final product, and the estimated quality costs. Finally, an illustrative example based on a manufacturing process demonstrates the applicability of this approach and several considerations are reported about future research directions.