A new approach of forecasting intermittent demand for spare parts inventories in the process industries

Accurate demand forecasting is of vital importance in inventory management of spare parts in process industries, while the intermittent nature makes demand forecasting for spare parts especially difficult. With the wide application of information technology in enterprise management, more information and data are now available to improve forecasting accuracy. In this paper, we develop a new approach for forecasting the intermittent demand of spare parts. The described approach provides a mechanism to integrate the demand autocorrelated process and the relationship between explanatory variables and the nonzero demand of spare parts during forecasting occurrences of nonzero demands over lead times. Two types of performance measures for assessing forecast methods are also described. Using data sets of 40 kinds of spare parts from a petrochemical enterprise in China, we show that our method produces more accurate forecasts of lead time demands than do exponential smoothing, Croston's method and Markov bootstrapping method.     

Joint optimization of level of repair analysis and spare parts stocks

In the field of after sales service logistics for capital goods, generally, METRIC type methods are used to decide where to stock spare parts in a multi-echelon repair network such that a target availability of the capital goods is achieved. These methods generate a trade-off curve of spares investment costs versus backorders. Backorders of spare parts lead to unavailability of the capital goods. Inputs in the spare parts stocking problem are decisions on (1) which components to repair upon failure and which to discard, and (2) at which locations in the repair network to perform the repairs and discards. The level of repair analysis (LORA) can be used to make such decisions in conjunction with the decisions (3) at which locations to deploy resources, such as test equipment that are required to repair, discard, or move components. Since these decisions significantly impact the spare parts investment costs, we propose to solve the LORA and spare parts stocking problems jointly. We design an algorithm that finds efficient solutions. In order for the algorithm to be exact and because of its computational complexity, we restrict ourselves to two-echelon, single-indenture problems. In a computational experiment, we show that solving the joint problem is worthwhile, since we achieve a cost reduction of over 43% at maximum (5.1% on average) compared with using a sequential approach of first solving a LORA and then the spare parts stocking problem.     

基于对故障规律统计分析的汽车备件需求预测

汽车备件的需求与汽车故障紧密相关,文章介绍了一种在对汽车故障进行统计分析并确定其分布规律的基础上预测备件需求的方法,预测中需要结合整车保有量的历史数据以及故障与备件的对应表。用统计的方法对某型客车的故障信息进行分析,认为故障的规律可用四种典型的分布进行描述。实例验证了这种方法的准确性高于传统方法,并且在计算机的辅助下可以方便操作。     

An inventory control system for spare parts at a refinery: An empirical comparison of different re-order point methods

Inventory control of spare parts is essential to many organizations, since excess inventory leads to high holding costs and stock outs can have a great impact on operations performance. This paper compares different re-order point methods for effective spare parts inventory control, motivated by a case study at a large oil refinery. Different demand modeling techniques and inventory policies are evaluated using real data.     

一种基于随机森林的备件预测模型研究

对舰船零部件发生故障问题进行故障诊断,并对故障诊断结果进行分析,建立舰船零部件备件需求模型,给出零部件之间的发生故障概率的关系与备件需求特征;将随机森林回归原理应用到了舰船零部件的备件需求预测领域,构建了基于随机森林的预测模型,以及预测结果准确率的评价。用诊断结果数据对算法进行验证,结果表明,将随机森林算法运用到舰船的备件预测领域可以为舰船装备在一次海上任务期内备件配置问题提供参考价值。     

修如新模型中备件量的计算及其置信上限的Fiducial推断

本文研究了在修如新模型下, 对预定贮存期为$T$同时开始贮存的$N$个系统, 给出在$P_0$可修复率下所需备件数的计算公式; 针对贮存寿命服从威布尔分布的系统, 利用枢轴量, 在$P_0$可修复率和预定贮存期为$T$的条件下, 给出$N$个系统所需备件数的置信上限的定义; 并基于系统寿命试验的完全样本, 利用Fiducial方法得出备件数置信上限的计算方法.     

基于贝塞尔曲线理论的备件需求模糊隶属度函数构建模型

用模糊理论描述备件需求是一种科学适用的方法,针对现有模糊变量隶属度函数构建方法的不足, 设计了基于贝塞尔曲线理论的备件需求模糊隶属度函数构建方法,给出了隶属度求解算法,分析了使拟合误差最小的控制点选择方法.同时通过实例验证以及与最小二乘法的对比分析,验证了贝塞尔曲线方法在构建备件需求模糊隶属度函数方面的有效性.此方法无需事先假设隶属度函数的形态,简单易用、使用灵活并且精度较高.     

Optimal lateral transshipment policies for a two location inventory problem with multiple demand classes

We consider an inventory model for spare parts with two stockpoints, providing repairable parts for a critical component of advanced technical systems. As downtime costs for these systems are expensive, ready–for–use spare parts are kept in stock to be able to quickly respond to a breakdown of a system. We allow for lateral transshipments of parts between the stockpoints upon a demand arrival. Each stockpoint faces demands from multiple demand classes. We are interested in the optimal lateral transshipment policy. There are three ways in which a demand can by satisfied: from own stock, via a lateral transshipment, or via an emergency procedure. Using stochastic dynamic programming, we characterize and prove the structure of the optimal policy, that is, the policy for satisfying the demands which minimizes the average operating costs of the system. This optimal policy is a threshold type policy, with state-dependent thresholds at each stockpoint for every demand class. We show a partial ordering in these thresholds in the demand classes. In addition, we derive conditions under which the so-called hold back and complete pooling policies are optimal, two policies that are often assumed in the literature. Furthermore, we study several model extensions which fit in the same modeling framework.     

An improved stochastic programming model for supply chain planning of MRO spare parts

The maintenance, repair and operation (MRO) spare parts that are vital to machine operations are playing an increasingly important role in manufacturing enterprises. MRO spare parts supply chain management planning must be coordinated to ensure spare part availability while keeping the total cost to a minimum. Due to the specificity of MRO spare parts, randomness and uncertainties in production and storage should be quantified to formulate the problem in a mathematical model. Given these considerations, this paper proposes an improved stochastic programming model for the supply chain planning of MRO spare parts. In our stochastic programming model, the following improvements are made: First, we quantify the uncertain production time capacity as a random variable with a probability distribution. Second, the upper bound of the storage cost is modeled as a multi-choice variable in the constraint. To derive the equivalent deterministic model, the Lagrange interpolating polynomial approach is used. The results of the numerical examples validate the feasibility and efficiency of the proposed model. Finally, the model is tested in the supply chain planning of continuous caster (CC) bearings.     

A stochastic model for joint spare parts inventory and planned maintenance optimisation

Spare parts demands are usually generated by the need of maintenance either preventively or at failures. These demands are difficult to predict based on historical data of past spare parts usages, and therefore, the optimal inventory control policy may be also difficult to obtain. However, it is well known that maintenance costs are related to the availability of spare parts and the penalty cost of unavailable spare parts consists of usually the cost of, for example, extended downtime for waiting the spare parts and the emergency expedition cost for acquiring the spare parts. On the other hand, proper planned maintenance intervention can reduce the number of failures and associated costs but its performance also depends on the availability of spare parts. This paper presents the joint optimisation for both the inventory control of the spare parts and the Preventive Maintenance (PM) inspection interval. The decision variables are the order interval, PM interval and order quantity. Because of the random nature of plant failures, stochastic cost models for spare parts inventory and maintenance are derived and an enumeration algorithm with stochastic dynamic programming is employed for finding the joint optimal solutions over a finite time horizon. The delay-time concept developed for inspection modelling is used to construct the probabilities of the number of failures and the number of the defective items identified at a PM epoch, which has not been used in this type of problems before. The inventory model follows a periodic review policy but with the demand governed by the need for spare parts due to maintenance. We demonstrate the developed model using a numerical example.     

Spare parts logistics and installed base information

Many of the challenges in spare parts logistics emerge due to the combination of large service networks, and sporadic/slow-moving demand. Customer heterogeneity and stringent service deadlines entail further challenges. Meanwhile, high revenue rates in service operations motivate companies to invest and optimize the service logistics function. An important aspect of the spare parts logistics function is its ability to support customer-specific requirements with respect to service deadlines. To support customer specific operations, many companies are actively maintaining and utilizing installed base data during forecasting, planning and execution stages. In this paper, we highlight the potential economic value of installed base data for spare parts logistics. We also discuss various data quality issues that are associated with the use of installed base data and show that planning performance depends on the quality dimensions.     

Forecasting for the ordering and stock-holding of spare parts

A modern military organization like the UK's Royal Air Force is dependent on readily available spare parts for in-service aircraft in order to maximize operational capability. A large proportion of spare parts are known to have an intermittent or slow-moving demand pattern, presenting particular problems as far as forecasting and inventory control are concerned. In this paper, we use extensive demand and replenishment lead-time data to assess the practical value of forecasting models put forward in the literature for addressing these problems. We use an analytical method for classifying the consumable inventory into smooth, irregular, slow-moving and intermittent demand patterns. Recent forecasting developments are compared against more commonly used methods across the identified demand patterns. One recently developed method, a modification to Croston's method referred to as the approximation method, is observed to provide significant reductions in the value of the stock-holdings required to attain a specified service level for all demand patterns.     

基于绩效保障模式的可修备件保障系统运营管理策略

基于绩效保障模式,设计了一个由备件仓库和维修车间组成的装备可修部件闭环保障系统,推导了备件库存水平状态的稳态概率分布,计算了可用度等几个保障绩效度量指标,建立了基于可用度约束的保障系统运作优化模型,并通过仿真分析探讨了保障系统运营管理策略问题。     

高原驻训航材有寿件需求预测研究

高原驻训航材保障中,有寿件重要度较高,部队必须携带足够的备件数量来满足任务需要.根据高原驻训条件下航材有寿件需求特点,将有寿件的需求分为到寿更换需求和随机故障消耗产生的需求两部分,分别用数学公式和仿真计算方法进行预测,再将两者结果相加为总需求量.通过实例分析验证,采用工程测算方法可以避免逐一分析器材寿命的繁杂,而单独考虑随机故障消耗可以进一步保证有寿件备件不短缺率在90%以上.该预测,该模型可以为航材有寿件到寿情况分析以及有寿件的携行方案制定提供参考.     

The final order problem for repairable spare parts under condemnation

We consider a manufacturer of complex machines that offers service contracts to her customers, committing herself to repair failed spare parts throughout a fixed service period. The suppliers of spare parts often discontinue the production of some parts as technology advances and ask the manufacturer to place a final order. We address the problem of determining final orders for such spare parts. The parts that we consider are repairable, but they are subject to the risk of condemnation. We build a transient Markovian model to represent the problem for a repairable spare part with a certain repair probability and repair lead time and we present some approximations that allow for further real-life characteristics to be included. Furthermore, an approximate model that can be computed more efficiently is presented, and the sensitivity of the results obtained with respect to the problem parameters is discussed, helping us develop several managerial insights.     

Spare parts management: Linking distributional assumptions to demand classification

Spare parts are known to be associated with intermittent demand patterns and such patterns cause considerable problems with regards to forecasting and stock control due to their compound nature that renders the normality assumption invalid. Compound distributions have been used to model intermittent demand patterns; there is however a lack of theoretical analysis and little relevant empirical evidence in support of these distributions. In this paper, we conduct a detailed empirical investigation on the goodness of fit of various compound Poisson distributions and we develop a distribution-based demand classification scheme the validity of which is also assessed in empirical terms. Our empirical investigation provides evidence in support of certain demand distributions and the work described in this paper should facilitate the task of selecting such distributions in a real world spare parts inventory context. An extensive discussion on parameter estimation related difficulties in this area is also provided.     

A hybrid spares demand forecasting method dedicated to mining industry

The paper addresses the problem of lumpy demand forecasting which is typical for spare parts. Several prediction methods are presented in the paper - traditional techniques based on time series and advanced methods which use artificial neural networks. The paper presents a new hybrid spares demand forecasting method dedicated to mining companies. The method combines information criteria, regression modeling and artificial neural networks. The paper also discusses simulation research related to efficiency assessment of the chosen variable selection methods and its application in the newly developed forecasting method. The assessment of this method is conducted by a comparison with traditional methods and is based on selected forecast errors.     

基于战役的多机种战伤备件需求模型

为了合理储备战时航材备件,通过分析战时故障备件的需求特点,改进了传统的单机故障备件需求模型.根据多机种协同作战任务的不同,引入备件工作运行比的概念,建立了基于作战任务的多机种故障备件需求模型.为解决多机种协同作战时的保障资源配置问题提供了思路和方法.     

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.     

Optimising a general repair kit problem with a service constraint

Field services are a particular type of after-sales service performed at the customer’s location where technicians repair malfunctioning machines. The inventory decisions about which spare part types to take to the repair site and in what quantities is called the repair kit problem. This problem is characterized by an order-based performance measure since a customer is only satisfied when all required spare parts are available to fix the machine. As a result, the service level in the decision making process is defined as a job fill rate. In this paper we derive a closed-form expression for the expected service level and total costs for the repair kit problem in a general setting, where multiple units of each part type can be used in a multi-period problem. Such an all-or-nothing strategy is a new characteristic to investigate, but commonly used in practice. Namely, items are only taken from the inventory when all items to perform the repair are available in the right quantity. We develop a new algorithm to determine the contents of the repair kit both for a service and cost model while incorporating this new expression for the job fill rate. We show that the algorithm finds solutions which differ on average 0.2% from optimal costs. We perform a case study to test the performance of the algorithm in practice. Our approach results in service level improvements of more than 30% against similar holding costs.