An extended optimal replacement model of systems subject to shocks

A system is subject to shocks that arrive according to a non-homogeneous Poisson process. As shocks occur a system has two types of failures: type I failure (minor failure) is rectified by a minimal repair, whereas type II failure (catastrophic failure) is removed by replacement. The probability of a type II failure is permitted to depend on the number of shocks since the last replacement. This paper proposes a generalized replacement policy where a system is replaced at the nth type I failure or first type II failure or at age T, whichever occurs first. The cost of the minimal repair of the system at age t depends on the random part C(t) and deterministic paper c(t). The expected cost rate is obtained. The optimal n¹ and optimal T¹ which would minimize the cost rate are derived and discussed. Various special cases are considered and detailed.     

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 δ-shock maintenance model for a deteriorating system

In this paper, a δ-shock maintenance model for a deteriorating system is studied. Assume that shocks arrive according to a renewal process, the interarrival time of shocks has a Weibull distribution or gamma distribution. Whenever an interarrival time of shocks is less than a threshold, the system fails. Assume further the system is deteriorating so that the successive threshold values are geometrically nondecreasing, and the consecutive repair times after failure form an increasing geometric process. A replacement policy N is adopted by which the system will be replaced by an identical new one at the time following the Nth failure. Then the long-run average cost per unit time is evaluated. Afterwards, an optimal policy N^* for minimizing the long-run average cost per unit time could be determined numerically.     

Optimization issues in k-out-of-n systems

The k-out-of-n system is a system consisting of n independent components such that the system works if and only if at least k of these n components are successfully running. Each component of the system is subject to shocks which arrive according to a nonhomogeneous Poisson process. When a shock takes place, the component is either minimally repaired (type 1 failure) or lying idle (type 2 failure). Assume that the probability of type 1 failure or type 2 failure depends on age. First, we investigate a general age replacement policy for a k-out-of-n system that incorporates minimal repair, shortage and excess costs. Under such a policy, the system is replaced at age T or at the occurrence of the (n-k + 1)th idle component, whichever occurs first. Moreover, we consider another model; we assume that the system operates some successive projects without interruptions. The replacement could not be performed at age T. In this case, the system is replaced at the completion of the Nth project or at the occurrence of the (n-k + 1)th idle component, whichever occurs first. For each model, we develop the long term expected cost per unit time and theoretically present the corresponding optimum replacement schedule. Finally, we give a numerical example illustrating the models we proposed. The proposed models include more realistic factors and extend many existing models.     

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 replacement policy for a deteriorating system with increasing repair times

This paper considers an optimal maintenance policy for a practical and reparable deteriorating system subject to random shocks. Modeling the repair time by a geometric process and the failure mechanism by a generalized δ-shock process, we develop an explicit expression of the long-term average cost per time unit for the system under a threshold-type replacement policy. Based on this average cost function, we propose a finite search algorithm to locate the optimal replacement policy N^∗ to minimize the average cost rate. We further prove that the optimal policy N^∗ is unique and present some numerical examples. Many practical systems fit the model developed in this paper.     

An optimal replacement policy for a multistate degenerative simple system

In this paper, a degenerative simple system (i.e. a degenerative one-component system with one repairman) with k + 1 states, including k failure states and one working state, is studied. Assume that the system after repair is not “as good as new”, and the degeneration of the system is stochastic. Under these assumptions, we consider a new replacement policy T based on the system age. Our problem is to determine an optimal replacement policy T^∗ such that the average cost rate (i.e. the long-run average cost per unit time) of the system is minimized. The explicit expression of the average cost rate is derived, the corresponding optimal replacement policy can be determined, the explicit expression of the minimum of the average cost rate can be found and under some mild conditions the existence and uniqueness of the optimal policy T^∗ can be proved, too. Further, we can show that the repair model for the multistate system in this paper forms a general monotone process repair model which includes the geometric process repair model as a special case. We can also show that the repair model in the paper is equivalent to a geometric process repair model for a two-state degenerative simple system in the sense that they have the same average cost rate and the same optimal policy. Finally, a numerical example is given to illustrate the theoretical results of this model.     

A number-dependent replacement policy for a system with continuous preventive maintenance and random lead times

This paper considers a number-dependent replacement policy for a system with two failure types that is replaced at the nth type I (minor) failure or the first type II (catastrophic) failure, whichever occurs first. Repair or replacement times are instantaneous but spare/replacement unit delivery lead times are random. Type I failures are repaired at zero cost since preventive maintenance is performed continuously. Type II failures, however, require costly system replacement. A model is developed for the average cost per unit time based on the stochastic behavior of the system and replacement, storage, and downtime costs. The cost-minimizing policy is derived and discussed. We show that the optimal number of type I failures triggering replacement is unique under certain conditions. A numerical example is presented and a sensitivity analysis is performed.     

A deteriorating cold standby repairable system with priority in use

In this paper, a cold standby repairable system consisting of two dissimilar components and one repairman is studied. In this system, it is assumed that the working time distributions and the repair time distributions of the two components are both exponential and component 1 is given priority in use. After repair, component 2 is “as good as new” while component 1 follows a geometric process repair. Under these assumptions, using the geometric process and a supplementary variable technique, some important reliability indices such as the system availability, reliability, mean time to first failure (MTTFF), rate of occurrence of failure (ROCOF) and the idle probability of the repairman are derived. A numerical example for the system reliability R(t) is given. And it is considered that a repair-replacement policy based on the working age T of component 1 under which the system is replaced when the working age of component 1 reaches T. Our problem is to determine an optimal policy T^∗ such that the long-run average cost per unit time of the system is minimized. The explicit expression for the long-run average cost per unit time of the system is evaluated, and the corresponding optimal replacement policy T^∗ can be found analytically or numerically. Another numerical example for replacement model is also given.     

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.     

A stocking policy for spare part provisioning under age based preventive replacement

A new policy, called stocking policy for ease of reference, has been advanced for joint optimization of age replacement and spare provisioning. It combines age replacement policy with continuous review (s, S) type inventory policy, where s is the stock reorder level and S is the maximum stock level. The policy is generally applicable to any operating situation having either a single item or a number of identical items. A simulation model has been developed to determine the optimal values of the decision variables by minimizing the total cost of replacement and inventory. The behaviour of the stocking policy has been studied for a number of case problems specifically constructed by 5-factor second order rotatory design and the effects of different cost elements and item failure characteristics have been highlighted. For all case problems, optimal (s, S) policies to-support the Barlow-Proschan age policy have also been determined. Simulation results clearly indicate that the optimal stocking policy is, in general, more cost-effective than the Barlow-Proschan policy.     

A replacement model for an additive damage model with restoration

A system existing in a random environment receives shocks at random points of time. Each shock causes a random amount of damage which accumulates over time. A breakdown can occur only upon the occurrence of a shock according to a known failure probability function. Upon failure the system is replaced by a new identical one with a given cost. When the system is replaced before failure, a smaller cost is incurred. Thus, there is an incentive to attempt to replace the system before failure. The damage process is controlled by means of a maintenance policy which causes the accumulated damage to decrease at a known restoration rate. We introduce sufficient conditions under which an optimal replacement policy which minimizes the total expected discounted cost is a control limit policy. The relationship between the undiscounted case and the discounted case is examined. Finally, an example is given illustrating computational procedures.     

Optimal replacement policy based on maximum repair time for a random shock and wear model

We study a \(\delta \) shock and wear model in which the system can fail due to the frequency of the shocks caused by external conditions, or aging and accumulated wear caused by intrinsic factors. The external shocks occur according to a Bernoulli process, i.e., the inter-arrival times between two consecutive shocks follow a geometric distribution. Once the system fails, it can be repaired immediately. If the system is not repairable in a pre-specific time D, it can be replaced by a new one to avoid the unnecessary expanses on repair. On the other hand, the system can also be replaced whenever its number of repairs exceeds N. Given that infinite operating and repair times are not commonly encountered in practical situations, both of these two random variables are supposed to obey general discrete distribution with finite support. Replacing the finite support renewal distributions with appropriate phase-type (PH) distributions and using the closure property associated with PH distribution, we formulate the maximum repair time replacement policy and obtain analytically the long-run average cost rate. Meanwhile, the optimal replacement policy is also numerically determined by implementing a two-dimensional-search process.     

Optimal replacement model with age-dependent failure type based on a cumulative repair-cost limit policy

This paper presents a replacement model with age-dependent failure type based on a cumulative repair-cost limit policy, whose concept uses the information of all repair costs to decide whether the system is repaired or replaced. As failures occur, the system experiences one of the two types of failures: a type-I failure (minor), rectified by a minimal repair; or a type-II failure (catastrophic) that calls for a replacement. A critical type-I failure means a minor failure at which the accumulated repair cost exceeds the pre-determined limit for the first time. The system is replaced at the nth type-I failure, or at a critical type-I failure, or at first type-II failure, whichever occurs first. The optimal number of minimal repairs before replacement which minimizes the mean cost rate is derived and studied in terms of its existence and uniqueness. Several classical models in maintenance literature are special cases of our model.     

Efficiency consideration of generalized age replacement policy

Under the generalized age replacement policy, the system is replaced either at the predetermined age or upon failure if its corresponding repair time exceeds the threshold, whichever comes first. In this paper, we investigate the optimal choice of the pre‐determined preventive replacement age for a nonwarranted system, which minimizes the expected cost rate during the life cycle of the system from the customer's perspective under certain cost structures. Furthermore, we discuss several properties of such a generalized age replacement policy in comparison with the traditional age replacement policy. An efficiency, which represents the fractional time that the system is on, is defined under the proposed generalized age replacement policy and its monotonicity properties are investigated as well. The main objective of this study is to investigate the advantageous features of the generalized age replacement policy over the traditional age replacement policy with regard to the availability of the repairable system. Assuming that the system deteriorates with age, we illustrate our proposed optimal policies numerically and observe the impact of relevant parameters on the optimal preventive replacement age.     

Hybrid block replacement and inspection policies for a multi-component system with heterogeneous component lives

Novel replacement policies that are hybrids of inspection maintenance and block replacement are developed for an n identical component series system in which the component parts used at successive replacements arise from a heterogeneous population. The heterogeneous nature of components implies a mixed distribution for time to failure. In these circumstances, a hybrid policy comprising two phases, an early inspection phase and a later wear-out replacement phase, may be appropriate. The policy has some similarity to burn-in maintenance. The simplest policy described is such a hybrid and comprises a block-type or periodic replacement policy with an embedded block or periodic inspection policy. We use a three state failure model, in which a component may be good, defective or failed, in order to consider inspection maintenance. Hybrid block replacement and age-based inspection, and opportunistic hybrid policies will also arise naturally in these circumstances and these are briefly investigated. For the simplest policy, an approximation is used to determine the long-run cost and the system reliability. The policies have the interesting property that the system reliability may be a maximum when the long-run cost is close to its minimum. The failure model implies that the effect of maintenance is heterogeneous. The policies themselves imply that maintenance is carried out more prudently to newer than to older systems. The maintenance of traction motor bearings on underground trains is used to illustrate the ideas in the paper.