Optimal maintenance policy and planned sale date for a machine subject to deterioration and random failure

The decision problem concerning the optimization of the maintenance policy and the selection of the sale date for a machine subject to deterioration and random failure is considered from a control-theoretic viewpoint. The originally stochastic optimal control problem is converted to a deterministic optimal control problem with the coefficients of the state and control variables modified in the performance index. The maximum principle is applied to derive the conditions for the optimal maintenance policy and for the optimal planned sale date. Economic interpretations of these conditions are presented in terms of marginal costs and revenues. An explicit solution is found analytically for the problem in the special case when the failure probability is independent of maintenance. The case of exponentially distributed life time for the machine is analyzed in full detail. Finally, the results are illustrated by an example.     

Extended optimal age-replacement policy with minimal repair of a system subject to shocks

An operating system is subject to shocks that arrive according to a non-homogeneous Poisson process. As shocks occur the system has two types of failure: type I failure (minor) or type II failure (catastrophic). A generalization of the age replacement policy for such a system is proposed and analyzed in this study. Under such a policy, if an operating system suffers a shock and fails at age y (⩽t), it is either replaced by a new system (type II failure) or it undergoes minimal repair (type I failure). Otherwise, the system is replaced when the first shock after t arrives, or the total operating time reaches age T (0 ⩽ t ⩽ T), whichever occurs first. The occurrence of those two possible actions occurring during the period [0, t] is based on some random mechanism which depends on the number of shocks suffered since the last replacement. The aim of this paper is to find the optimal pair (t¹, T¹) that minimizes the long-run expected cost per unit time of this policy. Various special cases are included, and a numerical example is given.     

A multi-objective approach for solving a replacement policy problem for equipment subject to imperfect repairs

This paper proposes a multi-objective approach to model a replacement policy problem applicable to equipment with a predetermined period of use (a planning horizon), which may undergo critical and non-critical failures. Corrective replacements and imperfect repairs are taken to restore the system to operation respectively when critical and non-critical failures occur. Generalized Renewal Process (GRP) is used to model imperfect repairs. The proposed model supports decisions on preventive replacement intervals and the number of spare parts purchased at the beginning of the planning horizon. A Multi-Objective Genetic Algorithm (MOGA) coupled with discrete event simulation (DES) is proposed to provide a set of solutions (Pareto-optimum set) committed to the different objectives of a maintenance manager in the face of a replacement policy problem, that is, maintenance cost, rate of occurrence of failures, unavailability, and investment on spare parts. The proposed MOGA is validated by an application example against the results obtained via the exhaustive approach. Moreover, examples are presented to evaluate the behavior of objective functions on Pareto set (trade-off analysis) and the impact of the repair effectiveness on the decision making.     

Optimal age-replacement time with minimal repair based on cumulative repair-cost limit for a system subject to shocks

An operating system is subject to random shocks that arrive according to a non-homogeneous Poisson process and cause the system failed. System failures experience to be divided into two categories: a type-I failure (minor), rectified by a minimal repair; or a type-II failure (catastrophic) that calls for a replacement. An age-replacement model is studied by considering both a cumulative repair-cost limit and a system’s entire repair-cost history. Under such a policy, the system is replaced at age T, or at the k-th type-I failure at which the accumulated repair cost exceeds the pre-determined limit, or at any type-II failure, whichever occurs first. The object of this article is to study analytically the minimum-cost replacement policy for showing its existence, uniqueness, and the structural properties. The proposed model provides a general framework for analyzing the maintenance policies, and presents several numerical examples for illustration purposes.     

Optimal maintenance scheduling for a complex manufacturing system subject to deterioration

We address the problem of determining inspection strategy and replacement policy for a deteriorating complex multi-component manufacturing system whose state is partially observable. We develop inspection and replacement scheduling models and other simple maintenance scheduling models via employing an imperfect repair model coupled with a damage process induced by operational conditions. The system state in performance of the imperfectly repaired system is modelled using a proportional intensity model incorporating a damage process and a virtual age process caused by repair. The system is monitored at periodic times and maintenance actions are carried out in response to the observed system state. Decisions to perform imperfect repair and replacement are based on the system state and crossing of a replacement threshold. The model proposed here aims at joint determination of a cost-optimal inspection and replacement policy along with an optimal level of maintenance which result in low maintenance cost and high operational performance and reliability of the system. To demonstrate the use of the model in practical applications a numerical example is provided. Solutions to optimal system parameters are obtained and the response of the model to these parameters is examined. Finally some features of the model are demonstrated. The approach presented provides a framework so that different scenario can be explored.     

Optimal age-replacement model with age-dependent type of failure and random lead time based on a cumulative repair-cost limit policy

In this paper, we consider an age-replacement model with minimal repair based on a cumulative repair cost limit and random lead time for replacement delivery. A cumulative repair cost limit policy uses information about a system’s entire repair cost history to decide whether the system is repaired or replaced; a random lead time models delay in delivery of a replacement once it is ordered. A general cost model is developed for the average cost per unit time based on the stochastic behavior of the assumed system, reflecting the costs of both storing a spare and of system downtime. The optimal age for preventive replacement minimizing that cost rate is derived, its existence and uniqueness is shown, and structural properties are presented. Various special cases are included, and a numerical example is given for illustration. Because the framework and analysis are general, the proposed model extends several existing results.     

A random review replacement model for a system subject to compound poisson shocks

We present a transform–free analysis of the following model. The state of the system is initially 0 and thereafter increases jumpwise due to compound Poisson shocks. Each shock increases the state by a random amount. The system is inspected at random points in time. If the state is above a threshold at an inspection, the system is replaced, otherwise no action is taken. Each replacement instantaneously brings the state back to 0. (Existing models assume either exponential interinspection times or discrete shock magnitudes.) This model can be applied to reliability, inventory, and queueing problems.Interpretations are given throughout to make the results easier to understand and to apply     

A note on a single-vendor and multiple-buyers production-inventory policy for a deteriorating item

In this note we examine the total cost function of a single-vendor multiple-buyers production-inventory policy for a deteriorating item by Yang and Wee [P.C. Yang and H.M. Wee, A single-vendor multiple-buyers production-inventory policy for a deteriorating item, European Journal of Operational Research 143 (2002) 570–581]. Two possible flaws in the cost function of Wee and Yang’s model are pointed out. A proposal to eradicate the flaws is given.     

A note on replacement policy for a system subject to non-homogeneous pure birth shocks

A system is subject to shocks that arrive according to a non-homogeneous pure birth process. As shocks occur, the system has two types of failures. Type-I failure (minor failure) is removed by a general repair, whereas type-II failure (catastrophic failure) is removed by an unplanned replacement. The occurrence of the failure type is based on some random mechanism which depends on the number of shocks occurred since the last replacement. Under an age replacement policy, a planned (or scheduled) replacement happens whenever an operating system reaches age T. The aim of this note is to derive the expected cost functions and characterize the structure of the optimal replacement policy for such a general setting. We show that many previous models are special cases of our general model. A numerical example is presented to show the application of the algorithm and several useful insights.     

A bivariate optimal replacement policy for a system subject to a generalized failure and repair process

Traditionally, in the studies of the optimal maintenance policies for repairable systems, the nonhomogeneous Poisson process model, which corresponds to the minimal repair process, has been intensively applied. However, in many practical situations, the repair type is not necessarily minimal. In this article, a new repair process based on a new counting process model (so‐called the generalized Polya process) is introduced. Then, the issue of the optimal replacement problem is discussed. A bivariate preventive replacement policy is developed and the properties of the optimal policy are studied. Illustrative examples are also presented. In addition, a comparison with a conventional replacement policy is performed.     

An extended stochastic failure model for a system subject to random shocks

In this article, a stochastic failure model for a system subject to a random shock process is studied. It is assumed that a fatal shock results in an immediate system failure, whereas a non-fatal shock may increase the susceptibility of the system to failure. The lifetime distribution of the system and its failure rate function are derived, and the effect of environmental factors on the failure process of the system is also investigated. Lifetimes of systems operated under different environmental conditions are stochastically compared.     

A PTAS for the chance-constrained knapsack problem with random item sizes

We consider a stochastic knapsack problem where each item has a known profit but a random size that is normally distributed independent of other items. The goal is to select a profit maximizing set of items such that the probability of the total size exceeding the knapsack bound is at most a given threshold. We present a Polynomial Time Approximation Scheme (PTAS) for the problem via a parametric LP reformulation that efficiently computes a solution satisfying the chance constraint strictly and achieving near-optimal profit.     

Minimizing makespan on a single machine subject to random breakdowns

We investigate optimal sequencing policies for the expected makespan problem with an unreliable machine, where jobs have to be reprocessed in their entirety if preemptions occur because of breakdowns. We identify a class of uptime distributions under which LPT minimizes expected makespan.     

Parameter estimation for partially observable systems subject to random failure

In this paper, we present a parameter estimation procedure for a condition‐based maintenance model under partial observations. Systems can be in a healthy or unhealthy operational state, or in a failure state. System deterioration is driven by a continuous time homogeneous Markov chain and the system state is unobservable, except the failure state. Vector information that is stochastically related to the system state is obtained through condition monitoring at equidistant sampling times. Two types of data histories are available — data histories that end with observable failure, and censored data histories that end when the system has been suspended from operation but has not failed. The state and observation processes are modeled in the hidden Markov framework and the model parameters are estimated using the expectation–maximization algorithm. We show that both the pseudolikelihood function and the parameter updates in each iteration of the expectation–maximization algorithm have explicit formulas. A numerical example is developed using real multivariate spectrometric oil data coming from the failing transmission units of 240‐ton heavy hauler trucks used in the Athabasca oil sands of Alberta, Canada. Copyright © 2012 John Wiley & Sons, Ltd.     

A condition-based replacement and spare provisioning policy for deteriorating systems with uncertain deterioration to failure

A new policy, referred to as the condition-based replacement and spare provisioning policy, is presented for deteriorating systems with a number of identical units. It combines the condition-based replacement policy with periodical inspections and the (S,s$S\text{,}s$) type inventory policy, noted as the (T,S,s,_Lp$T\text{,}S\text{,}s\text{,}{L}_{\text{p}}$) policy, where T is the inspection interval, S is the maximum stock level, s   is the reorder level, and _Lp$L_{\text{p}}$ is the preventive replacement threshold for the deterioration levels of units. The deterioration level of each unit in the system can be described by a scalar random variable, which is continuous and increasing monotonically. Furthermore, the deterioration level just when the unit failure occurs, termed deterioration to failure, is uncertain. Therefore, the condition-based reliability is proposed in order to characterize various and uncertain deterioration levels when unit failure occurs. A simulation model is developed for the system operation under the proposed condition-based replacement and spare provisioning policy. Thus, via the simulation method and the genetic algorithm, the decision variables T, S, s  , and _Lp$L_{\text{p}}$ can be jointly optimized for minimizing the cost rate. A case study is given, showing the procedure of applying the proposed policy and the condition-based reliability methodology to optimizing the maintenance scheme of haul truck motors at a mine site based on oil inspections, and proving beneficial for plant maintenance managers to reduce maintenance cost.     

Optimal Bayesian fault prediction scheme for a partially observable system subject to random failure

A new method for predicting failures of a partially observable system is presented. System deterioration is modeled as a hidden, 3-state continuous time homogeneous Markov process. States 0 and 1, which are not observable, represent good and warning conditions, respectively. Only the failure state 2 is assumed to be observable. The system is subject to condition monitoring at equidistant, discrete time epochs. The vector observation process is stochastically related to the system state. The objective is to develop a method for optimally predicting impending system failures. Model parameters are estimated using EM algorithm and a cost-optimal Bayesian fault prediction scheme is proposed. The method is illustrated using real data obtained from spectrometric analysis of oil samples collected at regular time epochs from transmission units of heavy hauler trucks used in mining industry. A comparison with other methods is given, which illustrates effectiveness of our approach.