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.     

Level of repair analysis and minimum cost homomorphisms of graphs

Level of repair analysis (LORA) is a prescribed procedure for defense logistics support planning. For a complex engineering system containing perhaps thousands of assemblies, sub-assemblies, components, etc. organized into several levels of indenture and with a number of possible repair decisions, LORA seeks to determine an optimal provision of repair and maintenance facilities to minimize overall life-cycle costs. For a LORA problem with two levels of indenture with three possible repair decisions, which is of interest in UK and US military and which we call LORA-BR, Barros [The optimisation of repair decisions using life-cycle cost parameters. IMA J. Management Math. 9 (1998) 403-413] and Barros and Riley [A combinatorial approach to level of repair analysis, European J. Oper. Res. 129 (2001) 242-251] developed certain branch-and-bound heuristics. The surprising result of this paper is that LORA-BR is, in fact, polynomial-time solvable. To obtain this result, we formulate the general LORA problem as an optimization homomorphism problem on bipartite graphs, and reduce a generalization of LORA-BR, LORA-M, to the maximum weight independent set problem on a bipartite graph. We prove that the general LORA problem is NP-hard by using an important result on list homomorphisms of graphs. We introduce the minimum cost graph homomorphism problem, provide partial results and pose an open problem. Finally, we show that our result for LORA-BR can be applied to prove that an extension of the maximum weight independent set problem on bipartite graphs is polynomial time solvable.     

“Optimization of aircraft maintenance/support infrastructure using genetic algorithms—level of repair analysis”

Level of repair analysis (LORA) is an approach used during the design stage of complex equipment for analysis of the cost effectiveness of competing maintenance strategies. LORA is carried as a part of the life cycle cost and cost of ownership analysis and plays a significant role in minimizing the life cycle cost and cost of ownership of the capital equipment. Since many purchasing decisions of complex equipment are based on cost of ownership, it has become essential to carry out LORA to compete in the market. In this paper, we develop a mathematical model for LORA and propose a solution methodology based on genetic algorithms. The concept is illustrated using a hypothetical aircraft engine.     

A systematic design methodology for generating the optimal repairs of aging aircraft

A design methodology which generates optimal mechanical repairs for aging aircraft is presented. Finite element modeling and analysis is used to evaluate the repairs. The repair problem is formulated as an optimization problem using an energy criterion. Optimal locations for rivet placement are found for many different situations.     

On sourcing and stocking policies in a two-echelon,multiple location,repairable parts supply chain

This research develops policies to minimize spare part purchases and repair costs for maintaining a fleet of mission-critical systems that operate from multiple forward (base) locations within a two-echelon repairable supply chain with a central depot. We take a tactical planning perspective to support periodic decisions for spare part purchases and repair sourcing, where the repair capabilities of the various locations are overlapping. We consider three policy classes: a central policy, where all repairs are sourced to a central depot; a local policy, whereby failures are repaired at forward locations; and a mixed policy, where a fraction of the parts is repaired at the bases and the remainder is repaired at the depot. Parts are classified based on their repair cost and lead time. For each part class, we suggest a solution that is based on threshold policies or on the use of a heuristic solution algorithm that extends the industry standard of marginal analysis to determine spare parts positioning by including repair fraction sourcing. A validation study shows that the suggested heuristic performs well compared to an exhaustive search (an average 0.2% difference in cost). An extensive numerical study demonstrates that the algorithm achieves costs which are lower by about 7–12% on average, compared to common, rule-based sourcing policies.     

A comparison of adaptive and stationary repair-cost limit criteria for a producer's warranty

A producer sells a product together with a warranty valid fora specified duration.Whenever the product fails during the warrantyperiod, the producer is responsible for making the product functional,either by replacing or repairing the equipment,according towhether the anticipated repair cost exceeds or does not exceeda specified repair-cost limit. It is assumed that repairs areminimal repairs, and that the distribution of repair costs isknown, as is the time-to-failure distribution of the product.In this paper, we compare two models in discrete time. The firstone involves an adaptive repair-cost limit which is set dynamicallyaccording to the age of the product, and the length of warrantyremaining. The second model assumes a constant or stationaryrepair-cost limit throughout the warranty period. Empiricalresults are summarized.     

The Repair Limit Replacement Method

In the repair limit replacement method when an item requires repair it is first inspected and the repair cost is estimated. Repair is only then undertaken if the estimated cost is less than the "repair limit". Dynamic programming methods are used in this paper as a general approach to the problem of determining optimum repair limits. Two problems are formulated and the cases of finite and infinite planning horizons and discounted and undiscounted costs are discussed. Methods are given for allowing for equipment availability and for the introduction of new types of equipment. An improved general formulation for finite time horizon, stochastic, dynamic programming problems is developed.     

Optimally maintaining a Markovian deteriorating system with limited imperfect repairs

We consider the problem of optimally maintaining a periodically inspected system that deteriorates according to a discrete-time Markov process and has a limit on the number of repairs that can be performed before it must be replaced. After each inspection, a decision maker must decide whether to repair the system, replace it with a new one, or leave it operating until the next inspection, where each repair makes the system more susceptible to future deterioration. If the system is found to be failed at an inspection, then it must be either repaired or replaced with a new one at an additional penalty cost. The objective is to minimize the total expected discounted cost due to operation, inspection, maintenance, replacement and failure. We formulate an infinite-horizon Markov decision process model and derive key structural properties of the resulting optimal cost function that are sufficient to establish the existence of an optimal threshold-type policy with respect to the system’s deterioration level and cumulative number of repairs. We also explore the sensitivity of the optimal policy to inspection, repair and replacement costs. Numerical examples are presented to illustrate the structure and the sensitivity of the optimal policy.     

Optimisation of integrated reverse logistics networks with different product recovery routes

The awareness of importance of product recovery has grown swiftly in the past few decades. This paper focuses on a problem of inventory control and production planning optimisation of a generic type of an integrated Reverse Logistics (RL) network which consists of a traditional forward production route, two alternative recovery routes, including repair and remanufacturing and a disposal route. It is assumed that demand and return quantities are uncertain. A quality level is assigned to each of the returned products. Due to uncertainty in the return quantity, quantity of returned products of a certain quality level is uncertain too. The uncertainties are modelled using fuzzy trapezoidal numbers. Quality thresholds are used to segregate the returned products into repair, remanufacturing or disposal routes. A two phase fuzzy mixed integer optimisation algorithm is developed to provide a solution to the inventory control and production planning problem. In Phase 1, uncertainties in quantity of product returns and quality of returns are considered to calculate the quantities to be sent to different recovery routes. These outputs are inputs into Phase 2 which generates decisions on component procurement, production, repair and disassembly. Finally, numerical experiments and sensitivity analysis are carried out to better understand the effects of quality of returns and RL network parameters on the network performance. These parameters include quantity of returned products, unit repair costs, unit production cost, setup costs and unit disposal cost.     

A Closed Queueing Maintenance Network with Two Repair Centres

In this paper we introduce a model to determine the maintenance float needed to maximize the availability of an operating system with N number of circulating units. An implicit enumeration algorithm is used as a solution technique to the closed queueing maintenance network with two types of repairs: minor and major repairs. It is shown that when there is no differentiation of repair type, this special case is obtained as a by-product of the two-repair-centre model. This paper assumes exponential failure times and exponential repair times with load-independent servers. The approach followed in this paper provides an approximate and simple way to solve the maintenance-float problem of this complex closed-network system.     

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.     

Utilizing Weibull Failure Rates in Repair Limit Analysis for Equipment Replacement/Preventive Maintenance Decisions

Repair limit analysis was originally proposed as a methodology for determining whether to repair or to replace an operating unit. The approach structures the problem as a Markov or semi-Markov decision process in which state-dependent repair limits trigger the replacement decision. Such a basic framework can easily be applied to more general equipment repair/overhaul environments in which typical maintenance condition monitoring information can serve as the overhaul trigger. One unnecessary limitation of repair limit analysis found in the literature is the use of a constant force of mortality within each state of the model. The purpose of this paper is to extend the repair limit analysis by incorporating a changing force of mortality as the unit ages. In this way, the analysis is more flexible in the parameter estimation phase and it is argued here more appealing since a changing (and usually increasing) force of mortality is utilized in equipment maintenance environments.     

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.     

Designing multi-echelon service parts networks with finite repair capacity

We propose an approach to model and solve the joint problem of facility location, inventory allocation and capacity investment in a two echelon, single-item, service parts supply chain with stochastic demand. The objective of the decision problem is to minimize the total expected costs associated with (1) opening repair facilities, (2) assigning each field service location to an opened facility, (3) determining capacity levels of the opened repair facilities, and (4) optimizing inventory allocation among the locations. Due to the size of the problem, computational efficiency is essential. The accuracy of the approximations and effectiveness of the approach are analyzed with two numerical studies. The approach provides optimal results in 90% of scenarios tested and was within 2% of optimal when it did not.We explore the impact of capacity utilization, inventory availability, and lead times on the performance of the approach. We show that including tactical considerations jointly with strategic network design resulted in additional cost savings from 3% to 12%. Our contribution is the development of a practical model and approach to support the decision making process of joint facility location and multi-echelon inventory optimization.     

A facility location and installation of resources model for level of repair analysis

The Level of Repair Analysis – LORA – is an analytic methodology aimed at determining: (i) the optimal location of facilities that compose a maintenance structure; (ii) the quantity of required resources in each facility; and (iii) the best repair policies, i.e., rules that determine if a given component should be discarded or repaired, and where those actions should take place. This work presents a mixed-integer programming model for LORA that is more comprehensive than others in the literature, being suitable to many practical situations. The model was applied to 15 substantial real world problems, and considering distinct maintenance policies to some of them, resulted in 22 different solutions, all of which could be achieved by a commercial Mixed-Integer Programming (MIP) solver in reasonable times.     

Optimal Claiming on Vehicle Insurance

Insurance companies charge reduced premiums to motorists who go through a period of one or more years without making a claim. When an accident occurs the insured frequently finds himself with the option of either making a claim and reverting to a higher premium or paying for the repair himself. Most motorists operate an informal system of "no-claim limits", whereby they only claim for repairs which exceed a certain cost.In this paper it is shown how, under reasonable assumptions regarding the rate of accidents and the distribution of repair costs, optimal no-claim limits can be determined. These minimise the long run average cost of premiums and repairs and show significant savings over the case where all claims are made. The effect of an "excess clause", whereby the insured agrees to pay a first amount of any claim is also studied, and rules for determining whether it is profitable to accept such a clause are presented in the form of a graph.     

An efficient model formulation for level of repair analysis

Given a product design and a repair network, a level of repair analysis (lora) determines for each component in the product (1) whether it should be discarded or repaired upon failure and (2) at which echelon in the repair network to do this. The objective of the lora is to minimize the total (variable and fixed) costs. We propose an ip model that generalizes the existing models, based on cases that we have seen in practice. Analysis of our model reveals that the integrality constraints on a large number of binary variables can be relaxed without yielding a fractional solution. As a result, we are able to solve problem instances of a realistic size in a couple of seconds on average. Furthermore, we suggest some improvements to the lora analysis in the current literature.     

Workforce-constrained maintenance scheduling for military aircraft fleet: a case study

The problem is related to a fleet of military aircraft with a certain flying program in which the availability of the aircraft sufficient to meet the flying program is a challenging issue. During the pre- or after-flight inspections, some component failures of the aircraft may be found. In such cases, the aircraft are sent to the repair shop to be scheduled for maintenance jobs, consisting of failure repairs or preventive maintenance tasks. The objective is to schedule the jobs in such a way that sufficient number of aircrafts is available for the next flight programs. The main resource, as well as the main constraint, in the shop is skilled-workforce. The problem is formulated as a mixed-integer mathematical programming model in which the network flow structure is used to simulate the flow of aircraft between missions, hanger and repair shop. The proposed model is solved using the classical Branch-and-Bound method and its performance is verified and analyzed in terms of a number of test problems adopted from the real data. The results empirically supported practical utility of the proposed model.     

The Decision to Repair or Scrap a Machine

A simple algebraic formula for combining repair data with prior experience determines the time when a machine should be replaced in order to minimize the expected cost of equipment purchase and maintenance. A random sample from an exponential distribution represents the cost of each repair, and a time-dependent Poisson process represents the intervals between repairs. Bayes' formula provides the basis for combining data with previous judgement about the characteristics of the equipment. Automobile maintenance records support the basic assumptions of the model, and illustrate the method of deciding when to scrap a given machine.     

Two shock and wear systems under repair standing a finite number of shocks

A shock and wear system standing a finite number of shocks and subject to two types of repairs is considered. The failure of the system can be due to wear or to a fatal shock. Associated to these failures there are two repair types: normal and severe. Repairs are as good as new. The shocks arrive following a Markovian arrival process, and the lifetime of the system follows a continuous phase-type distribution. The repair times follow different continuous phase-type distributions, depending on the type of failure. Under these assumptions, two systems are studied, depending on the finite number of shocks that the system can stand before a fatal failure that can be random or fixed. In the first case, the number of shocks is governed by a discrete phase-type distribution. After a finite (random or fixed) number of non-fatal shocks the system is repaired (severe repair). The repair due to wear is a normal repair. For these systems, general Markov models are constructed and the following elements are studied: the stationary probability vector; the transient rate of occurrence of failures; the renewal process associated to the repairs, including the distribution of the period between replacements and the number of non-fatal shocks in this period. Special cases of the model with random number of shocks are presented. An application illustrating the numerical calculations is given. The systems are studied in such a way that several particular cases can be deduced from the general ones straightaway. We apply the matrix-analytic methods for studying these models showing their versatility.