Optimal maintenance of a production-inventory system with idle periods

In this paper we consider a production-inventory system in which an input generating installation supplies a buffer with a raw material and a production unit pulls the raw material from the buffer with constant rate. The installation deteriorates in time and the problem of its optimal preventive maintenance is considered. It is assumed that the installation after the completion of its maintenance remains idle until the buffer is evacuated. Under a suitable cost structure it is shown that the average-cost optimal policy for fixed buffer content is of control-limit type, i.e. it prescribes a preventive maintenance of the installation if and only if its degree of deterioration is greater than or equal to a critical level. Using the usual regenerative argument, the average cost of a control-limit policy is computed exactly and then, the optimal control-limit policy is determined. Furthermore, the stationary probabilities of the system under the optimal policy are computed.     

Optimal maintenance of two stochastically deteriorating machines with an intermediate buffer

We consider a manufacturing system in which an input generating installation transfers a raw material to a subsequent production unit. Both machines deteriorate stochastically with usage and may fail. For each machine the deteriorating process is described by some known transition probabilities between different degrees of deterioration. A buffer has been built between the two machines in order to cope with unexpected failures of the installation. A discrete-time Markov decision model is formulated for the optimal preventive maintenance of both machines. The maintenance times are geometrically distributed and the cost structure includes operating costs, storage costs, maintenance costs and costs due to the lost production. It is proved that for fixed buffer content and for fixed deterioration degree of one machine, the average-cost optimal policy initiates a preventive maintenance of the other machine if and only if its degree of deterioration exceeds some critical level. We study, by means of numerical results, the effect of the variation of some parameters on the optimal policy and on the minimum average cost. For the case in which the maintenance times follow continuous distributions, an approximate discrete-time Markov decision model is proposed.     

An improved algorithm for the computation of the optimal repair/replacement policy under general repairs

We consider a system which deteriorates with age and may experience a failure at any time instant. On failure, the system may be replaced or repaired. The repair can partially reset the failure intensity of the unit. Under a suitable cost structure it has been proved in the literature that the average-cost optimal policy is of control-limit type, i.e. it conducts a replacement if and only if, on the nth failure, the real age of the system is greater than or equal to a critical value. We develop an efficient special-purpose policy iteration algorithm that generates a sequence of improving control-limit policies. The value determination step of the algorithm is based on the embedding technique. There is strong numerical evidence that the algorithm converges to the optimal policy.     

Computation of the Optimal Policy for the Control of a Compound Immigration Process through Total Catastrophes

In this paper we consider a Markov decision model introduced by Economou (2003), in which it was proved that the optimal policy in the problem of controlling a compound immigration process through total catastrophes is of control-limit type. We show that the average cost of a control-limit policy is unimodal as a function of the critical point. This result enables us to design very efficient algorithms for the computation of the optimal policy as the bisection procedure and a special-purpose policy iteration algorithm that operates on the class of control-limit policies.AMS 2000 Subject Classification: Primary 9OC40; Secondary 6OJ25     

Joint determination of optimal safety stocks and production policy for an imperfect production system

In this article, we develop an imperfect economic manufacturing quantity (EMQ) model for an unreliable production system subject to process deterioration, machine breakdown and repair and buffer stock. The basic model is developed under general process shift, machine breakdown and repair time distributions. We suggest a computational algorithm for determination of the optimal safety stock and production run time which minimize the expected cost per unit time in the steady state. For a numerical example, we illustrate the outcome of the proposed model and perform a sensitivity analysis with respect to the model-parameters which have direct influence on the optimal decisions.     

A Markov decision algorithm for optimal inspections and revisions in a maintenance system with partial information

This paper deals with a gradually deteriorating equipment whose actual degree of deterioration can be revealed by inspections only. An inspection can be succeeded by a revision depending on the system's degree of deterioration. In the absence of inspections and revisions, the working condition of the system evolves according to a Markov chain whose changes of state are not observable with the possible exception of a breakdown. Examples of this model include production machines subject to stochastic breakdowns, and maintenance of communication systems. The cost structure of the model consists of inspection, revision and operating costs. It is intuitively reasonable that in many applications a simple control-limit rule will be optimal. Such a rule prescribes a revision only when inspection reveals that the degree of deterioration has exceeded some critical level. A special-purpose Markov decision algorithm operating on the class of control-limit rules is developed for the computation of an average cost optimal schedule of inspections and revisions.     

Monotone optimal replacement policies for a Markovian deteriorating system in a controllable environment

We consider the optimal replacement of a periodically inspected system under Markov deterioration that operates in a controlled environment. Provided are sufficient conditions that characterize an optimal control-limit replacement policy with respect to the system’s condition and its environment. The structure of the optimal policy is illustrated by a numerical example.     

Optimal lot size and inspection policy for products sold with warranty

This paper develops a mathematical model to jointly determine the optimal lot size and product inspection policy for a deteriorating production system, when products are sold with free minimal repair warranty. Due to system deterioration, a last-K product inspection scheme is proposed, under which the last K products in a production lot are inspected and nonconforming products found are reworked. Based on the model, we show that there exist a unique optimal lot size and a corresponding inspection policy such that the expected total cost per unit time is minimized. Since there is no closed-form expression for the optimal lot size, an upper bound and approximate solutions are obtained to facilitate the search process. Furthermore, an algorithm is provided to efficiently search for the optimal policy and the performance of the optimal policy is evaluated through numerical examples.     

Age-dependent production planning and maintenance strategies in unreliable manufacturing systems with lost sale

In this paper, we formulate an analytical model for the joint determination of an optimal age-dependent buffer inventory and preventive maintenance policy in a production environment that is subject to random machine breakdowns. Traditional preventive maintenance policies, such as age and periodic replacements, are usually studied based on simplified and non-realistic assumptions, as well as on the expected costs criterion. Finished goods inventories and the age-dependent likelihood of machine breakdowns are usually not considered. As a result, these policies could significantly extend beyond the anticipated financial incomes of the system, and lead to crises. In order to solve this problem, a more realistic analysis model is proposed in this paper to consider the effects of both preventive maintenance policies and machine age on optimal safety stock levels. Hence, a unified framework is developed, allowing production and preventive maintenance to be jointly considered. We use an age-dependent optimization model based on the minimization of an overall cost function, including inventory holdings, lost sales, preventive and corrective maintenance costs. We provide optimality conditions for the manufacturing systems considered, and use numerical methods to obtain an optimal preventive maintenance policy and the relevant age-dependent threshold level production policy. In this work, this policy is called the multiple threshold levels hedging point policy. We include numerical examples and sensitivity analyses to illustrate the importance and the effectiveness of the proposed methodology. Compared with other available optimal production and maintenance policies, the numerical solution obtained shows that the proposed age-dependent optimal production and maintenance policies significantly reduce the overall cost incurred.     

On a production-inventory system of deteriorating items subject to random machine breakdowns with a fixed repair time

This paper considers the impact of random machine breakdowns on the classical Economic Production Quantity (EPQ) model for a product subject to exponential decay and under a no-resumption (NR) inventory control policy. A product is manufactured in batches on a machine that is subject to random breakdowns in order to meet a constant demand over an infinite planning horizon. The product is assumed to have a significant rate of deterioration and time to deterioration is described by an exponential distribution. Also, the time-to-breakdown is a random variable following an exponential distribution. Under the NR policy, when a breakdown occurs during a production run, the run is immediately aborted. A new run will not be started until all available inventories are depleted. Corrective maintenance of the production system is carried out immediately after a breakdown and it takes a fixed period of time to complete such an activity. The objective is to determine the optimal production uptime that minimizes the expected total cost per unit time consisting of setup, corrective maintenance, inventory carrying, deterioration, and lost sales costs. A near optimal production uptime is derived under conditions of continuous review, deterministic demand, and no shortages.     

Controlling the GI/M/1 queue by conditional acceptance of customers

In this paper we consider the problem of controlling the arrival of customers into a GI/M/1 service station. It is known that when the decisions controlling the system are made only at arrival epochs, the optimal acceptance strategy is of a control-limit type, i.e., an arrival is accepted if and only if fewer than n customers are present in the system. The question is whether exercising conditional acceptance can further increase the expected long run average profit of a firm which operates the system. To reveal the relevance of conditional acceptance we consider an extension of the control-limit rule in which the nth customer is conditionally admitted to the queue. This customer may later be rejected if neither service completion nor arrival has occurred within a given time period since the last arrival epoch. We model the system as a semi-Markov decision process, and develop conditions under which such a policy is preferable to the simple control-limit rule.     

Optimal Breast Biopsy Decision-Making Based on Mammographic Features and Demographic Factors

Breast cancer is the most common non-skin cancer affecting women in the United States, where every year more than 20 million mammograms are performed. Breast biopsy is commonly performed on the suspicious findings on mammograms to confirm the presence of cancer. Currently, 700,000 biopsies are performed annually in the U.S.; 55%-85% of these biopsies ultimately are found to be benign breast lesions, resulting in unnecessary treatments, patient anxiety, and expenditures. This paper addresses the decision problem faced by radiologists: When should a woman be sent for biopsy based on her mammographic features and demographic factors? This problem is formulated as a finite-horizon discrete-time Markov decision process. The optimal policy of our model shows that the decision to biopsy should take the age of patient into account; particularly, an older patient's risk threshold for biopsy should be higher than that of a younger patient. When applied to the clinical data, our model outperforms radiologists in the biopsy decision-making problem. This study also derives structural properties of the model, including sufficiency conditions that ensure the existence of a control-limit type policy and nondecreasing control-limits with age.     

On optimal operating conditions for a data processing system: A stochastic approach

In this paper, we consider the problem of determining optimal operating conditions for a data processing system. The system is burned‐in for a fixed burn‐in time before it is put into field operation and, in field operation, it has a work size and follows an age‐replacement policy. Assuming that the underlying lifetime distribution of the system has a bathtub‐shaped failure rate function, the properties of optimal burn‐in time, optimal work size and optimal age‐replacement policy will be derived. It can be seen that this model is a generalization of those considered in the previous works, and it yields a better optimal operating conditions. This paper presents an analytical method for three‐dimensional optimization problem. An algorithm for determining optimal operating conditions is also given. Copyright © 2007 John Wiley & Sons, Ltd.     

部分延迟订购的易变质品联合定价与生产策略

构建了一个需求同时依赖于销售价格和库存水平,生产率和变质率均为常数,允许缺货且缺货量部分延迟订购的易变质品联合定价与生产控制模型。首先证明了在销售价格给定的情况下,系统的总利润函数是关于生产计划的严格凹函数,平均利润函数是严格的伪凹函数,即存在唯一的最优解,并给出其充分条件。接着给出问题的一个数值求解算法。最后通过算例,展示了模型及相关算法的应用,并对相关参数进行了灵敏度分析,结果显示:当产品的生产成本、缺货成本和机会成本增加时,系统的平均利润将下降;生产成本和延迟订购阻力系数对最优定价和生产策略以及平均利润的影响较大。     

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本文考虑了一个其产品保修期内免费小修的退化 生产系统的定期检修策略. 系统的退化过程包括三个状态: 可控制状态, 不可控制状态, 故障状态. 过程呆在可控制状态和不可控制状态的时间假设都服从指数分布. 生产系统在固定的时刻t或发生故障时进行检修, 两者以先发生为准. 本文讨论了使单位产品每周期期望成本最小的最优定期检修时间本文考虑了一个其产品保修期内免费小修的退化生产系统的定期检修策略.系统的退化过程包括三个状态:可控制状态,不可控制状态,故障状态.过程呆在可控制状态和不可控制状态的时间假设都服从指数分布.生产系统在固定的时刻t﹡或发生故障时进行检修,两者以先发生为准.本文讨论了使单位产品每周期期望成本最小的最优定期检修时间t﹡,三种特殊情况显示了最优值t的性质.此外,灵敏性分析和数字实例说明了模型中的参数对最优定期检修策略的影响.     

Economic Production Lot Size Model with Variable Production Rate and Imperfect Quality

The classical economic production lot size (EPL) model assumes a constant production rate that is predetermined and inflexible, and perfect quality. Recent models have removed the assumption of perfect quality while maintaining the inflexible production rate assumption. Production rates in many cases, such as orders filled by a machine, can be changed. Moreover, unit production cost and process quality depend on the production rate. In this paper, we extend the EPL model to cases where the production rate is a decision variable. Unit production cost becomes a function of the production rate. Also, the quality of the production process deteriorates with increased production rate. We solve the proposed model for special cost and quality functions and illustrate the results with a numerical example. The results show that, for cases where increases in the production rate lead to a significant deterioration in quality, the optimal production rate may be smaller than the rate that minimizes unit production cost. For cases where quality is largely independent of the production rate, the optimal production rate may be larger than the rate that minimizes unit production cost.     

3.1. OR in banking

In this paper, we describe a deterministic multiperiod capacity expansion model in which a single facility serves the demand for many products. Potential applications for the model can be found in the capacity expansion planning of communication systems as well as in the production planning of heavy process industries. The model assumes that each capacity unit simultaneously serves a prespecified (though not necessarily integer) number of demand units of each product. Costs considered include capacity expansion costs, idle capacity holding costs, and capacity shortage costs. All cost functions are assumed to be nondecreasing and concave. Given the demand for each product over the planning horizon, the objective is to find the capacity expansion policy that minimizes the total cost incurred. We develop a dynamic programming algorithm that finds optimal policies. The required computational effort is a polynomial function of the number of products and the number of time periods. When the number of products equals one, the algorithm reduces to the well-known algorithm for the classical dynamic lot size problem.     

Optimal dynamic routing in Flexible Manufacturing Systems with limited buffers

An optimal routing policy is obtained for Flexible Manufacturing Systems (FMSs) with limited buffers at the work stations. This policy is used to effectively drive a robotic material handling system. The routing decisions are made by a supervising computer on a real-time basis in order to avoid any work station running out of inputs and to control the blocking of the material handling system. Using our model, general material handling times can be assumed. The optimal policy and several key performance measures are computed, following the problem formulation as a continuous-time, semi-Markovian decision process. Fast convergence and computational stability are ensured by the ergodic solution algorithm augmented to solve the functional equations of the renewal process. The solution algorithm was implemented, tested on an extensive range of problems regarding the structure and the performance of the optimal policy. Complex environments involving diverse processing times, as well as very limited buffer storage, were examined. The interaction between the allocation of buffer spaces to work stations, the structural properties of the optimal monotone (threshold-type) policy and the system performance are also investigated.     

An EOQ model with backorders and all-units discounts

In this paper we study an inventory model with backorders where the purchase unit price depends on the ordered quantity. This situation appears in practice when a salesperson offers a fixed compensation to a client for not losing the sale and there are quantity discounts. The optimal policy is obtained through a sequential optimization procedure in two stages that relies on a quadratic function (first stage) and on the objective function of the classical EOQ model (second stage). An algorithm is developed for the model and some extensions are commented.