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Optimising production cost and end‐product quality when raw material quality is varying

This paper deals with the optimisation of production processes in a situation where the raw material varies. The objective is to minimise production costs for a given raw material quality, with restrictions on the end‐product quality. Three important issues are addressed. First, we discuss the collection of data for response surface modelling. In full‐scale production processes it is very difficult to perform large experiments. We show that merging smaller designed experiments can be a good alternative. Second, we illustrate the use of an approach for combining data obtained using an experimental design with spectroscopic raw material measurements in a joint regression model. Finally, we discuss some issues related to robustness and sensitivity in optimisation. We also show how this optimisation can be used as a tool when purchasing raw materials. Copyright © 2007 John Wiley & Sons, Ltd.