Maintenance models in warranty: A literature review

Along with increasing the warranty period for complex systems, reducing the warranty servicing costs has become an issue of great importance to the manufacturers. One possible way to reduce the expected warranty servicing cost is by making sound decision on the product warranty and maintenance strategies. Therefore, warranties (basic warranty and extended warranty) and maintenance (corrective and preventive) are strongly interlinked and of great interest to both manufacturers and customers. This paper is the first identifiable academic literature review to deal with warranty and maintenance. It provides a classification scheme for the articles that link warranty and maintenance published between 2001 and 2011 covering 44 journals and proposes a taxonomy scheme to classify these articles. Nine hundred articles were identified for their relevance to warranty and were carefully reviewed. One-hundred and twenty-two articles were subsequently selected for their relevance to maintenance and included in the classification.     

Optimal maintenance strategy under renewable warranty with repair time threshold

In this paper, we consider a periodic preventive maintenance model, from the manufacturer's perspective, which can be implemented to reduce the maintenance cost of a repairable product during a given warranty period. The product is assumed to deteriorate with age and the warranty policy we adopt in this paper takes into account the two factors of failure time and repair time of the product when the product failure occurs. Under the proposed two-factor warranty, a repair time threshold is pre-determined and if the repair takes more time than that of the threshold, the failed product is replaced with a renewed warranty policy. Otherwise, the product is only minimally repaired to return to the operating state. During such a renewable warranty period, preventive maintenance is conducted to reduce the rate of degradation periodically while the product is in operation. By assuming certain cost structures, we formulate the expected warranty cost during the warranty period from the manufacturer's perspective when a periodic preventive maintenance strategy is adapted. Although more frequent preventive maintenance increases the warranty cost, the chance of product failures would be reduced. The main aim of this paper is to accomplish the optimal trade-off between the warranty cost and the preventive maintenance period by determining the optimal preventive maintenance period that minimizes the total expected warranty cost during the warranty period. Assuming the power law process for the product failures, we illustrate our proposed maintenance model numerically and study the impact of relevant parameters on the optimal preventive maintenance policy.     

Maintenance optimization for second‐hand products following periodic imperfect preventive maintenance warranty period

The maintenance policy for a product's life cycle differs for second‐hand and new products. Although several maintenance policies for second‐hand products exist in the literature, they are rarely investigated with reference to periodic inspection and preventive maintenance action during the warranty period. In this research, we study an optimal post‐warranty maintenance policy for a second‐hand product, which was purchased at age x with a fixed‐length warranty period. During the warranty period, the product is periodically inspected and maintained preventively at a prorated cost borne by the user, while any product failure is only minimally repaired by the dealer. After the warranty expires, the product is self‐maintained by the user for a fixed‐length maintenance period and the costs incurred during this time are fully borne by the user. At the end of the maintenance period, the product is replaced with a product of the user's choice. This study is focused on the determination of an optimal length for the maintenance period after the warranty expiration. As a criterion for the optimality, we adopt the long‐run mean cost during the second‐hand product's life cycle from the user's perspective. Finally, our results are analyzed numerically for sensitive analysis of several relevant factors, assuming that the failure distribution follows a Weibull distribution.     

基于两类失效的产品保修策略与出保维修优化

基于消费者对保修的需求,设计消费者偏爱的保修策略是制造商巩固市场地位、提升市场竞争力的一种战略决策。与此同时,以较低费用制定较长出保服役时间的出保维修策略也是消费者一直追求的目标。本文以两类失效产品为研究对象,首先从制造商角度将消费者偏爱的更新免费更换保修策略与产品定价相融合,开展了产品保修策略设计。其次,从消费者角度将预防维修与经典周期更换策略相融合,提出了维修—周期更换策略,且将其作为出保维修策略并对相应的性能进行了说明。通过数值实验发现,利润模型可对保修开展设计;与总费用模型作为目标函数相比,费用率模型作为目标函数可降低寿命周期费用;与经典周期更换策略相比,提出的维修—周期更换策略能使出保服役时间更长、费用率更低。     

Optimal system design considering warranty,periodic preventive maintenance,and minimal repair

This paper presents a cost minimisation model for an optimal design of a mixed series-parallel system with deteriorating components. The model incorporates warranty, periodic preventive maintenance, and minimal repair in the design of system configuration. Imperfect repair is adopted to model the effect of preventive maintenance. Both free and pro-rata warranty policies are considered. A numerical example is given to demonstrate the application of this model.     

基于视情维修的质保政策设计研究

随着产品同质化程度不断提升,完善的质保服务已成为厂商提升品牌形象、刺激用户购买需求和全面反馈市场信息的主要途径。本文以具有退化特性的耐用品为研究对象,建立了视情维修条件下性能退化的维纳过程模型,考虑产品价格、质保期长度和维修费用承担比例对产品需求的影响,以最大化厂商利润为目标,确定了最优的质保期长度和维修费用承担比例。结合算例,比较了无视情维修和提供视情维修两种情形下对应的厂商利润,并分析了产品退化速率、成本参数和产品价格对利润的影响。研究结果表明,在质保服务范围内提供合理的视情维修服务既可将产品可靠性维持在一个较高水平,又可显著提升厂商利润。     

Optimal preventive-maintenance warranty policy for repairable products

This paper investigates preventive-maintenance warranty (PMW) policies for repairable products. When the length of a warranty period is pre-specified, the optimal number of preventive maintenance actions, corresponding maintenance degrees, and the maintenance schedule are jointly determined. We show that there exists a unique optimal policy such that the expected total warranty cost is minimized. Under some reasonable conditions, structural properties of the optimal policy are obtained. Using these properties, an algorithm is provided to efficiently search for the optimal policy. In the case where the failure density is Weibull, a closed form expression of the optimal policy is derived. Finally, the impact of providing preventive maintenance within a warranty period is illustrated through a numerical example.     

Optimal warranty policies for systems with imperfect repair

We investigate a system whose basic warranty coverage is minimal repair up to a specified warranty length. An additional service is offered whereby first failure is restored up to the consumers’ chosen level of repair. The problem is studied under two system replacement strategies: periodic maintenance before and after warranty. It turns out that our model generalizes the model of Rinsaka and Sandoh [K. Rinsaka, H. Sandoh, A stochastic model with an additional warranty contract, Computers and Mathematics with Applications 51 (2006) 179–188] and the model of Yeh et al. [R.H. Yeh, M.Y. Chen, C.Y. Lin, Optimal periodic replacement policy for repairable products under free-repair warranty, European Journal of Operational Research 176 (2007) 1678–1686]. We derive the optimal maintenance period and optimal level of repair based on the structures of the cost function and failure rate function. We show that under certain assumptions, the optimal repair level for additional service is an increasing function of the replacement time. We provide numerical studies to verify some of our results.     

Optimization of a fully adaptive quality and maintenance model in the presence of multiple location and scale quality shifts

This paper presents a new model for the economic-statistical optimization of a Variable-Parameter Shewhart control scheme. The proposed model can be utilized to monitor processes where apart from multiple independent assignable causes, affecting both the mean and variance, failures can also occur. Each time an alarm is issued by the control scheme, preventive maintenance actions are initiated, whereas, corrective maintenance actions are required after a failure. The more realistic assumption of imperfect preventive maintenance actions has been considered. The optimal parameter values are selected through a bi-objective optimization problem formulated by the long-run average cost per time unit minimization, and the long-run expected availability maximization, subject to statistical constraints. A real case example is presented to illustrate the application of the model. An extended numerical investigation is utilized to evaluate the superiority of the proposed model.     

Modeling and analysis of a warranty policy using new and reconditioned parts

Remanufacturing processes such as refurbishing and reconditioning can extend the life of a product returned from the field. This provides financial opportunities and allows manufacturers to engage in sustainable practices. However, the inability to access a sufficient quantity of reconditioned components from end‐of‐life products can force the concurrent utilization of new components. This paper deals with the determination of an optimal warranty policy where a mixture of new and reconditioned components are used to carry out replacements upon failure for products under warranty. A mathematical optimization model is developed to maximize the manufacturer's expected total profit based on four decision variables: the warranty length, the sale price, the age of reconditioned components, and the proportion of reconditioned components to be used. A numerical procedure is used to compute the optimal solution. Numerical results are provided and discussed to demonstrate the validity and the added value of the proposed approach. Copyright © 2016 John Wiley & Sons, Ltd.     

Warranty cost analysis: Increasing warranty repair times

In this study, we model the warranty servicing costs under nonrenewing and renewing free repair warranties. We assume nonzero increasing repair times with the warranty cost depending on the length of the repair time. An increasing geometric process is used to model the consecutive repair times. We introduce the generalised alternating renewal process, which is an alternating process with cycles consisting of an item's operational time followed by the corresponding repair time. We derive analytical results for a generalised alternating renewal process with a finite time horizon and use them to evaluate the warranty costs over the warranty period and over the life cycle of the product under the nonrenewing free repair warranty and renewing free repair warranty. Properties of the model are demonstrated through a simulation study and through the application to warranty claims data from an automotive manufacturer.     

考虑更新延长两阶段保修的二手产品维修策略优化

针对二手产品的维修问题,给出了二手产品生命周期的定义,提出了考虑更新延长两阶段保修的维修策略模型。该策略综合考虑了产品的年龄变化、延保折扣、小修和生产损失费用等因素,从顾客的角度出发,建立以顾客期望总费用率最小化为目标的免费更换保修和按比例更换保修两种策略模型,并给出模型最优化的相关理论证明。算例研究验证了模型的有效性,并对参数的灵敏度进行了分析,文中结论可为顾客进行产品维修计划提供决策依据。     

Dynamic pricing and warranty policies for products with fixed lifetime

We consider a repairable product with known market entry and departure times. A warranty policy is offered with product purchase, under which a customer can have a failed item repaired free of charge in the warranty period. It is assumed that customers are heterogeneous in their risk attitudes toward uncertain repair costs incurred after the warranty expires. The objective is to determine a joint dynamic pricing and warranty policy for the lifetime of the product, which maximizes the manufacturer’s expected profit. In the first part of the analysis, we consider a linearly decreasing price function and a constant warranty length. We first study customers’ purchase patterns under several different pricing strategies by the manufacturer and then discuss the optimal pricing and warranty strategy. In the second part, we assume that the warranty length can be altered once during the product lifetime in developing a joint pricing and warranty policy. Numerical studies show that a dynamic warranty policy can significantly outperform a fixed-length warranty policy.     

A general age-replacement model with minimal repair under renewing free-replacement warranty

A general age-replacement model in which incorporates minimal repair, planned and unplanned replacement, is considered in this paper for products under a renewing free-replacement warranty policy. For both warranted and non-warranted products, cost models from the user’s perspective are developed, and the corresponding optimal replacement ages are derived such that the long-run expected cost rate is minimized. The impacts of a product warranty on the optimal replacement model are investigated analytically. Furthermore, we show that the optimal replacement age for a warranted product is closer to the end of the warranty period than for a non-warranted product. Finally, numerical examples are given for illustration.     

Asymptotic behavior of repairable device systems under warranty and beyond warranty periods

Positivity - In this paper, we present a new mathematical model generalizing the model of a single unit repairable device system, with preventive maintenance under warranty period, and the model of...     

Cost analysis on renewable full-service warranties for multi-component systems

This paper presents a novel warranty policy named ‘full-service warranty’ (FSW) for repairable multi-component systems under which the failed component(s) or subsystem(s) will be replaced, in addition, a (perfect) maintenance action will be performed to reduce the chance of future system failure, both free of charge to consumers. Such a policy is desirable for both consumers and manufacturers since consumers receive better warranty service compared to the traditional free repair policy, at the same time, manufacturers may enjoy increase in sale as well as cost-saving due to improved product reliability by the maintenance action. Under the renewable FSW policy, from manufacturers’ point of view, cost models for complex systems with series, parallel, series–parallel (s–p) and parallel–series (p–s) structure are developed. Exact expressions for the first and second centered moments of warranty cost per product sold are obtained. Sensitivity analysis is performed based on a numerical example.     

A new preventive maintenance strategy for items sold under warranty

When products are sold under warranty, the manufacturer incursadditional costs for warranty servicing. Preventive maintenanceactions can be used to reduce this cost and these are worthwhileonly if the extra cost incurred is less than the reduction achieved.In this paper we propose a new preventive maintenance policywhere the parameters are selected optimally to minimize thetotal warranty servicing cost.     

新产品定价决策的影响因素分析

新产品的成功销售取决于两个重要的因素:一是具有生产特性的工程变量,比如产品的可靠性水平;一是具有市场特征的影响因素,比如价格和保障机制。为了实现收益,制造商必须认真审视价格、产品可靠性和保障机制的选择。因此,本文将价格作为外生变量,将保障机制与可靠性作为决策变量,建立了以最大化为目标的收益模型,分析可靠性与保障机制的最优策略。另外,探讨当不同变量的敏感性参数发生变化时,最优保障机制与产品可靠性的变化规律。最后,通过算例分析收益函数的基本特性,结论显示消费者总是从产品保障机制的信号中判断产品的可靠性水平,这对新产品销售有一定的借鉴意义。     

按比例保修策略下多保修期差别定价研究

保修策略是联系厂商和顾客的一种合同责任,它往往用于促进产品的销售。产品保修期长短与其定价有着紧密的联系。本文在考虑一个厂商采用按比例保修策略及设定多个保修期的基础上,以产品的保修期和价格为决策变量,以厂商收益最大化为目标,研究了产品故障次数成指数分布下最优保修期和价格的组合策略,并通过算例比较了差别定价和单一定价下厂商的收益。最后,通过灵敏度分析,研究了消费者保修期偏移弹性对厂商收益所产生的影响。     

Last time buy decisions for products sold under warranty

Manufacturers supplying products under warranty need a strategy to deal with failures during the warranty period: repair the product or replace it by a new one, depending on e.g. age and/or usage of the failed product. An (implicit) assumption in virtually all models is that new products to replace the failed ones are immediately available at given replacement costs. Because of the short life cycles of many products, manufacturing may be discontinued before the end of the warranty period. At that point in time, the supplier has to decide how many products to put on the shelf to replace failed products under warranty that will be returned from the field (the last time buy decision). This is a trade-off between product availability for replacement and costs of product obsolescence. In this paper, we consider the joint optimization of repair-replacement decisions and the last time buy quantity for products sold under warranty. We develop approximations to estimate the total relevant costs and service levels for this problem, and show that we can easily find near-optimal last time buy quantities using a numerical search. Comparison to discrete event simulation results shows an excellent performance of our methods.