Delay time model for determining the effectiveness of a system under adverse conditions of production and inspection

The effectiveness of production is influenced by different events that may disrupt the original production plan, such as degradation in the production process, additional demands and inspection errors. To analyze the impact of these issues on production planning, we propose a delay time model for a single-component system that can experience four different states: good, minor defective, major defective and failed. The model uses cost-rate as a measure of production effectiveness. We conducted an investigation into the consequences of the degradation process, specifically focusing on its impact on the generation of nonconforming products. Additionally, we examined the effects of additional demands on the rate of rework products and analyzed the impact of inspection errors, including both the induction and non-detection of defects. These issues represent adverse conditions that many production systems run into their operation and maintenance processes. The results of our study advise the best strategies to deal with these adverse conditions in order to minimize their impacts on effectiveness of a production system. The proposed model serves as a guide and illustrative example of how these issues can be incorporated in the process of optimizing the effectiveness of production. From this perspective, this paper’s main contribution is a series of insights that widens the manager’s view about the production process in a real system, in which perfect and suitable conditions are not commonly present.