Economic Design of Single Sampling Plan and Quick Switching System Under Zero Inflated Poisson Distribution

Objectives: This article focuses on designing a plan and system based on the Zero-Inflated Poisson (ZIP) distribution, aiming to determine the optimal sample size, acceptance number, and economic cost. Methods: The study employs the ZIP distribution as the baseline due to its suitability for scenarios with excessive zero defects during inspection. Sampling plans are developed using the ZIP distribution for both single sampling and the Quick Switching System (QSS). The economic cost function is derived and optimized for each system, with numerical examples provided to illustrate the optimal total cost. Findings: The QSS designed under the ZIP distribution is found to be more cost-efficient compared to the single sampling plan based on the Poisson distribution. The proposed system achieves an optimal total cost, effectively managing zero-inflated defect scenarios in modern production processes. Novelty: This work applies the ZIP distribution to address zero defects in high-quality manufacturing and introduces a cost-optimized framework for sampling plans and systems. Thus, in shop-floor situations, both producers and consumers can benefit from this model, making decisions with minimal total cost. Keywords: Acceptance Sampling Plan, Economic Cost, Operating Ratio, Quick Switching Single Sampling System, Zero-Inflated Poisson Distribution