Trade-off between inventory and repair capacity in spare part networks

The availability of repairable technical systems depends on the availability of (repairable) spare parts, to be influenced by (1) inventory levels and (2) repair capacity. In this paper, we present a procedure for simultaneous optimisation of these two factors. Our method is based on a modification of the well-known VARI-METRIC procedure for determining near-optimal spare part inventory levels and results for multi-class, multi-server queuing systems representing repair shops. The modification is required to avoid non-convexity problems in the optimisation procedure. To include part-time and overtime working, we allow for a non-integer repair capacity. To this end, we develop a simple approximation for queuing systems with a non-integer number of servers. Our computational experiments show that the near-optimal utilisation rate of the repair servers is usually high (0.80–0.98) and depends mainly on the relative price of the servers compared with inventory items. Further, the size of the repair shop (the minimal number of servers required for a stable system) plays its part. We also show that our optimisation procedure is robust for the choice of the step size for the server capacity.     

Repairable inventory theory: Models and applications

Repairable inventory theory involves designing inventory systems for items which are repaired and returned to use rather than discarded. Such systems are composed of items which are typically less expensive to repair than to replace, and are considerably more complicated than traditional inventory systems. The typical problem is concerned with the optimal stocking of the repairable parts and the location of these stocks, given that there may be multiple locations. An added dimension to the problem is the determination of the size and location(s) of the repair capacity for these parts. Further, different performance measures may be used, such as cost, backorders, and availability. There are many complicating factors in the design of repairable inventory systems, for example, not all failed units can be repaired and put back into service, some will be condemned and have to be replaced by new procurements. Various solution approaches have been developed to solve the problem, few have been implemented in practice, and no single model has addressed all or most of the complicating factors. Recent trends in the repairable inventory environment, environmental trends and regulations, and trends in product design are calling some of the assumptions of earlier models into question. In this paper we discuss the existing body of literature on repairable inventory, examine the various models proposed and the major assumptions made in those models, and classify them according to their solution methodology, single versus multi-echelon, and exact versus approximate solutions. It is intended to aid practitioners and researchers in identifying the sources for existing methods and the suitability of those to their application, as well as identify areas for additional research.     

A study of repairable parts inventory system operating under performance-based contract

Performance-Based Logistics (PBL) is becoming a dominant logistics support strategy, especially in the defense industry. PBL contracts are designed to serve the customer’s key performance measures, while the traditional contracts for after-sales services, such as Fixed-price (FP) and Cost-plus (C+), only provide insurance or incentive. In this research, we develop an inventory model for a repairable parts system operating under a PBL contract. We model the closed-loop inventory system as an M/M/m queue in which component failures are Poisson distributed and the repair times at the service facility are exponential. Our model provides the supplier and the customer increased flexibility in achieving target availability. Analysis of key parameters suggests that to improve the availability of the system with repairable spare parts, the supplier should work to improve the components reliability and efficiency of repair facility, rather than the base stock level, which has minimal impact on system availability.     

Inventory with service time and transfer of customers and/inventory

An inventory system with two parallel service facilities is considered. A certain number of customers are transferred from longer to shorter queue whenever their difference reaches a prescribed quantity. Along with this customer transfer, a certain quantity of inventory is also transferred, depending on availability. Further, if one of the queues has customers, but has no inventoried items whereas the other has at least one inventoried item to spare, then exactly one item is taken to the former and service begins thereby enhancing the efficiency of the system. Stability of the system is analysed. Several performance measures that helps in efficient design of such systems, are computed. Some numerical results are provided.     

Replacement times and costs in a degrading system with several types of failure: The case of phase-type holding times

A reliability system submitted to external and internal failures, that can be repairable or non-repairable, with degradation levels, and with sojourn times phase-type distributed, is considered. Repair is not as good as new, and the repair of internal failure follows policy N, that is, after N completed repairs the system is replaced by a new one to the following failure, repairable or not. For this system, a Markov model is constructed, and the stationary probability vector is calculated. It is shown that the distribution of the time between two consecutive replacements follows a phase-type distribution, whose representation is determined. The costs of these periods are calculated. An optimization problem involving the costs, the availability, and the number of internal repairs is illustrated by a numerical example.     

Optimal repair–replacement policies for a system with two types of failures

In this paper, the optimal replacement problem is investigated for a system with two types of failures. One type of failure is repairable, which is conducted by a repairman when it occurs, and the other is unrepairable, which leads to a replacement of the system at once. The repair of the system is not “as good as new”. The consecutive operating times of the system after repair form a decreasing geometric process, while the repair times after failure are assumed to be independent and identically distributed. Replacement policy N is adopted, where N is the number of repairable failures. The system will be replaced at the Nth repairable failure or at the unrepairable failure, whichever occurs first. Two replacement models are considered, one is based on the limiting availability and the other based on the long-run average cost rate of the system. We give the explicit expressions for the limiting availability and the long-run average cost rate of the system under policy N, respectively. By maximizing the limiting availability A(N) and minimizing the long-run average cost rate C(N), we theoretically obtain the optimal replacement policies N^∗ in both cases. Finally, some numerical simulations are presented to verify the theoretical results.     

Reliability-based measures for a retrial system with mixed standby components

In this paper, we consider a retrial and repairable multi-component system with mixed warm and cold standby components. It is assumed that the failure times of primary (operating) and warm standby components follow exponential distributions. When a component fails, it is sent to a service station with a single server (repairman) and no waiting space. The failed component is repaired if the server is idle and it has to enter an orbit if the server is busy. The failed component in the orbit will try to get the repair service again after an exponentially distributed random time period. The repair time also has an exponential distribution. The mean time-to-failure, MTTF, and the steady-state availability, A_T(∞), are derived in this retrial and repairable system. Using a numerical example, we compare the systems with and without retrials in terms of the cost/benefit ratios. Sensitivity analysis for the mean time-to-failure and the steady-state availability are investigated as well.     

Using an Expert System to Monitor an Automatic Stock Control System

The theory of the control of stock is well understood, and a large number of firms use automatic stock control and ordering techniques as a major part of their inventory control systems. However, the effectiveness of such automatic stock control systems depends on the correct selection of system parameters for each item in the inventory and on the accurate reporting of information. It is not unusual for errors to be made in both the selection of parameters and the entry of data, and regular failures of either can cause severe problems in stock control. It is generally difficult for a human stock controller to discover errors quickly because of the large number of items that is usually found in a company inventory. This paper describes the use of an expert system to examine stock records and diagnose anomalies in the data provided or parameters applied to individual items in a stock control system. The expert system ‘reasons’ from symptoms such as reports from the forecasting system or high stock levels, to defects in the stock model used or data-collection processes, and from there to possible remedial action. Results are presented for runs of the expert system on a simulated stock control system.     

Towards a normative model for inventory cost management in a generalized ABC classification system

This paper establishes a general ABC inventory classification system as the foundation for a normative model of the maintenance cost structure and stock turnover characteristics of a large, multi-item inventory system with constant demand. For any specified number of inventory classes, the model allows expression of the overall system combined ordering and holding cost in terms of (i) the re-ordering frequencies for the items in each inventory class and (ii) the inventory class structure, that is, the proportion of the total system's items that are in each inventory class. The model yields a minimum total maintenance cost function, which reflects the effect of class structure on inventory maintenance costs and turnover. If the Pareto curve (a.k.a. Distribution-by-value function) for the inventory system can be expressed (or approximated) analytically, the model can also be used to determine an optimal class structure, as well as an appropriate number of inventory classes. A special case of the model produces a simply structured, class-based ordering policy for minimizing total inventory maintenance costs. Using real data, the cost characteristics of this policy are compared to those of a heuristic, commonly used by managers of multi-item inventory systems. This cost comparison, expressed graphically, underscores the need for normative modelling approaches to the problem of inventory cost management in large, multi-item systems.     

A reliability semi‐Markov model involving geometric processes

We consider a semi‐Markov process that models the repair and maintenance of a repairable system in steady state. The operating and repair times are independent random variables with general distributions. Failures can be caused by an external source or by an internal source. Some failures are repairable and others are not. After a repairable failure, the system is not as good as new and our model reflects that. At a non‐repairable failure, the system is replaced by a new one. We assume that external failures occur according to a Poisson process. Moreover, there is an upper limit N of repairs, it is replaced by a new system at the next failure, regardless of its type. Operational and repair times are affected by multiplicative rates, so they follow geometric processes. For this system, the stationary distribution and performance measures as well as the availability and the rate of occurrence of different types of failures in stationary state are calculated. Copyright © 2002 John Wiley & Sons, Ltd.     

An algorithm for repairable item inventory system with depot spares and general repair time distribution

We consider the problem of determining the initial spare inventory level for a multi-echelon repairable item inventory system. We extend the previous results to the system, which has an inventory at the central depot as well as at bases and with a general repair time distribution. We propose an algorithm which finds spare inventory level to minimize the total expected cost and simultaneously to satisfy a specified minimum service rate. Extensive computational experiments show that the algorithm is accurate and efficient.     

A deteriorating cold standby repairable system with priority in use

In this paper, a cold standby repairable system consisting of two dissimilar components and one repairman is studied. In this system, it is assumed that the working time distributions and the repair time distributions of the two components are both exponential and component 1 is given priority in use. After repair, component 2 is “as good as new” while component 1 follows a geometric process repair. Under these assumptions, using the geometric process and a supplementary variable technique, some important reliability indices such as the system availability, reliability, mean time to first failure (MTTFF), rate of occurrence of failure (ROCOF) and the idle probability of the repairman are derived. A numerical example for the system reliability R(t) is given. And it is considered that a repair-replacement policy based on the working age T of component 1 under which the system is replaced when the working age of component 1 reaches T. Our problem is to determine an optimal policy T^∗ such that the long-run average cost per unit time of the system is minimized. The explicit expression for the long-run average cost per unit time of the system is evaluated, and the corresponding optimal replacement policy T^∗ can be found analytically or numerically. Another numerical example for replacement model is also given.     

Reliability of repairable multi-state two-phase mission systems with finite number of phase switches

In this article, a repairable multi-state two-phase mission system with finite number of phase switches is considered. System states can be divided into a subset of working states and a subset of failed states, and the system can be repaired from the failed subset to the working subset. However, when the number of switches between two phases exceeds a specified integer, the system will be permanently damaged and cannot be repaired any more. The closed-form formulas of the probability density function of the time to first failure of the system, the point-wise availability, the interval availability and other reliability indexes are obtained by using the theory of aggregated stochastic processes. Finally, a detailed example of lithium-ion batteries is given to illustrate the proposed model and obtained results.     

Using repair priorities to reduce stock investment in spare part networks

In this paper, we examine the impact of repair priorities in spare part networks. Several heuristics for assigning priorities to items as well as optimising stock levels are developed, extending the well-known VARI-METRIC method. We model repair shops by multi-class, multi-server priority queues. A proper priority setting may lead to a significant reduction in the inventory investment required to attain a target system availability (usually 10–20%). The saving opportunities are particularly high if the utilisation of the repair shops is high and if the item types sharing the same repair shop have clearly different characteristics (price, repair time). For example, we find an investment reduction of 73% for a system with single server repair shops with an utilisation of 0.90 that handle five different item types.     

A general model for consecutive-k-out-of-n: F repairable system with exponential distribution and (k−1)-step Markov dependence

In this paper, a general model for consecutive-k-out-of-n: F repairable system with exponential distribution and (k−1)-step Markov dependence is introduced. The lifetime of a component is an exponential random variable, its parameter depends on the number of consecutive failed components that precede the component. The repair time is also an exponential random variable. A priority repair rule on the basis of the system failure risk is adopted. Then the transition density matrix of the system is determined. Some reliability indices, including the system availability, rate of occurrence of failures and reliability are evaluated accordingly. For the demonstration of the model and methodology, a linear system example and a circular system example are investigated.     

Approximate Solution of a Single-Base Multi-indentured Repairable-item Inventory System

In this paper we model a single-base multi-indentured repairable item inventory system. The base has a maximum number of identical on-line machines, and each machine consists of several module types. Our objective is to calculate the steady-state operating characteristics of the system. The usual Markovian approach leads to multidimensional state spaces that are large even for relatively small problems. Solving such a multidimensional system is very difficult because of the huge number of states. Consequently, we propose an approximation technique that allows us to solve large problems relatively quickly. Although the resulting solution is only approximate, a variety of test problems indicates that the algorithm is quite accurate.     

The impact of fleet size on performance-based incentive management

Performance-based contracting (PBC) is envisioned to lower the asset ownership cost while ensuring desired system performance. System availability, widely used as a performance metric in such contracts, is affected by multiple factors such as equipment reliability, spares stock, fleet size, and service capacity. Prior studies have either focussed on ensuring parts availability or advocating the reliability allocation during design. This paper investigates a single echelon repairable inventory model in PBC. We focus on reliability improvement and its interaction with decisions affecting service time, taking into account the operating fleet size. The study shows that component reliability in a repairable inventory system is a function of the operating fleet size and service rate. A principal-agent model is further developed to evaluate the impact of the fleet size on the incentive mechanism design. The numerical study confirms that the fleet size plays a critical role in determining the penalty and cost sharing rates when the number of backorders is used as the negative incentive scheme.     

同时考虑故障相关和变故障率的可修系统可靠性计算

基于Copula相关性理论,考虑可修系统零部件工作寿命、故障部件修复时间之间的正相关性,且将零件工作寿命、修复时间放宽到一般连续分布,而不局限于指数分布.提出微时间差t→t+△t内系统一步状态转移矩阵概念,进而演算出状态转移密度矩阵,经系统状态方程,分别给出了任意时刻t单部件、串联型、二不同单元和一修理工组成的并联可修系统的可用度和稳态可用度计算模型.通过算例,说明该理论方法的可行性.     

Reliability Analysis of the Retrial Queue with Server Breakdowns and Repairs

Retrial queues have been widely used to model many problems arising in telephone switching systems, telecommunication networks, computer networks and computer systems, etc. It is of basic importance to study reliability of retrial queues with server breakdowns and repairs because of limited ability of repairs and heavy influence of the breakdowns on the performance measure of the system. However, so far the repairable retrial queues are analyzed only by queueing theory. In this paper we give a detailed analysis for reliability of retrial queues. By using the supplementary variables method, we obtain the explicit expressions of some main reliability indexes such as the availability, failure frequency and reliability function of the server. In addition, some special queues, for instance, the repairable M/G/1 queue and repairable retrial queue can be derived from our results. These results may be generalized to the repairable multi-server retrial models.     

Controlling multi-indenture repairable inventories of multiple aircraft parts

This paper presents a model for determining stock levels of repairable items supporting a fleet of commercial aircraft operated by a transportation company in the Philippines. The items are characterised by infrequent demand, high cost and a hierarchical (or indentured) structure. The system has three re-supply sources of serviceable parts, namely, the in-house repair shop, the out-house repair shops, and the suppliers. Non-repairable items are scrapped and replaced with new items on a one-for-one basis. The model considers two levels of indenture represented by modules and components. The objective is to minimise the total expected steady-state annual cost of holding inventories and of aircraft delays. A minimum requirement on module availability is also applied. The formulation is such that the regular discrete optimisers available could not be readily used to solve it. The model is implemented on an illustrative problem, employing an integer search for the item stock levels within a limited range.