An ideal way of obtaining an optimal inspection permutation for a system with components connected in series

The problem of an inspection permutation or inspection strategy (first discussed in a research paper in 1989 and reviewed in another research paper in 1991) is revisited. The problem deals with an N‐component system whose times to failure are independent but not identically distributed random variables. Each of the failure times follows an exponential distribution. The components in the system are connected in series such that the failure of at least one component entails the failure of the system. Upon system failure, the components are inspected one after another in a hierarchical way (called an inspection permutation) until the component causing the system to fail is identified. The inspection of each component is a process that takes a non‐negligible amount of time and is performed at a cost. Once the faulty component is identified, it is repaired at a cost, and the repair process takes some time. After the repair, the system is good as new and is put back in operation. The inspection permutation that results in the maximum long run average net income per unit of time (for the undiscounted case) or maximum total discounted net income per unit of time (for the discounted case) is called the optimal inspection permutation/strategy. A way of determining an optimal inspection permutation in an easier fashion, taking advantage of the improvements in computer software, is proffered. Mathematica is used to showcase how the method works with the aid of a numerical example. Copyright © 2016 John Wiley & Sons, Ltd.     

Optimum preventive maintenance policies maximizing the mean time to the first system failure for a two-unit standby redundant system

A two-unit standby redundant system with repair and preventive maintenance is considered under the following assumptions: (I) the inspection of an operative unit is made only if the other unit is in standby; and (II) an operative unit, which forfeited inspection due to assumption (I), undergoes inspection just upon repair completion of the failed unit (or inspection completion). We derive the Laplace-Stieltjes transform of the cumulative distribution function of the time to the first system failure and the mean time to the first system failure. Further, we obtain the necessary and sufficient conditions for an optimum preventive maintenance policy to exist with respect to the mean time to the first system failure. More importantly, under certain conditions, we find the analytical form of an optimum inspection time maximizing the mean time to the first system failure. A numerical example is presented.The work reported in this article was supported by the National Institutes of Health under Grant No. GM-16197-05. The authors would like to express their appreciation to Professor D. L. Jaquette and Professor R. Vasudevan, University of Southern California, for their advice and encouragement.     

A condition based maintenance model for a two-unit series system

This paper discusses a condition based maintenance model with exponential failures and fixed inspection intervals for a two-unit system in series. The condition of each unit, such as vibration or heat, is monitored at equidistant time intervals. The condition indicator variables for each unit are used to decide whether to repair an individual unit or to overhaul the whole system. After a maintenance action is performed the monitored condition indicator variable takes on its initial value. Each unit can fail only once within an inspection interval and when one or both units fail the system fails. The probability of failure is exponential and the failure rate is dependent on the condition. The cost to be minimized is the long-run average cost of maintenance actions and failures. We study the optimal solution to this problem obtained via dynamic programming.     

考虑不完美检测的两阶段点检与备件订购策略联合优化

针对设备维修与备件管理相互影响与制约的问题, 在基于延迟时间理论的基础上, 提出了两阶段点检与备件订购策略联合优化。点检是不完美的, 当点检识别设备的缺陷状态时, 进行预防更新; 设备故障时, 进行故障更新。结合设备更新时备件的状态, 采用更新报酬理论建立了以第一阶段点检时间、第二阶段点检周期和备件订购时间为决策变量, 以最小化单位时间期望成本为目标的模型。最后, 通过人工蜂群算法对模型求解, 并在数值分析中将两阶段点检策略与定期点检策略进行比较, 结果表明:两阶段点检策略始终优于定期点检策略, 验证了所建模型的有效性。     

A two-phase inspection policy with imperfect testing

This paper presents an inspection policy to detect failures of a single component system that remain hidden otherwise. Inspection reveals whether the unit is in good or failed state. The possibility of non perfect testing is assumed, thus, successive inspections may fail detecting a failure or result in a false alarm. The occurrence of false alarms is reported in optical fire detectors and inspection of printing circuit boards which are on the basis of electronic systems. A two-phase inspection schedule takes into account the changes in component’s aging. The system may undergo different inspection frequencies to detect both early failures or those due to the natural deterioration in the system as time goes by. The examples reveal the advantages of a two-phase inspection when comparing with the unique interval inspection.     

Optimal inspection policy for three-state systems monitored by control charts

This paper presents the formulations of the expected long-run cost per time unit for a system monitored by a static control chart and by an adaptive control chart respectively. The static chart has a fixed sampling interval and a fixed sample size. The adaptive chart has a fixed sample size but variable sampling intervals. The system is supposed to have three states, normal working state, failure delay time state, and failed state. Two levels of repair are used to maintain the system. A minor repair is used to restore the system if a detectable defect is confirmed by an inspection. A major repair will be performed if the system fails. The expected cost per time unit for maintaining such a system is obtained. The objective of such analysis is to find an optimal sampling policy for the inspection process. An artificially generated data example and a real data example are used to compare the expected cost per time unit for both the static and adaptive control charts.     

The last departure time from an M t /G/∞ queue with a terminating arrival process

This paper studies the last departure time from a queue with a terminating arrival process. This problem is motivated by a model of two-stage inspection in which finitely many items come to a first stage for screening. Items failing first-stage inspection go to a second stage to be examined further. Assuming that arrivals at the second stage can be regarded as an independent thinning of the departures from the first stage, the arrival process at the second stage is approximately a terminating Poisson process. If the failure probabilities are not constant, then this Poisson process will be nonhomogeneous. The last departure time from an M _t /G/∞ queue with a terminating arrival process serves as a remarkably tractable approximation, which is appropriate when there are ample inspection resources at the second stage. For this model, the last departure time is a Poisson random maximum, so that it is possible to give exact expressions and develop useful approximations based on extreme-value theory.      

Inspection scheduling for imperfect production processes under free repair warranty contract

The paper considers scheduling of inspections for imperfect production processes where the process shift time from an ‘in-control’ state to an ‘out-of-control’ state is assumed to follow an arbitrary probability distribution with an increasing failure (hazard) rate and the products are sold with a free repair warranty (FRW) contract. During each production run, the process is monitored through inspections to assess its state. If at any inspection the process is found in ‘out-of-control’ state, then restoration is performed. The model is formulated under two different inspection policies: (i) no action is taken during a production run unless the system is discovered in an ‘out-of-control’ state by inspection and (ii) preventive repair action is undertaken once the ‘in-control’ state of the process is detected by inspection. The expected sum of pre-sale and post-sale costs per unit item is taken as a criterion of optimality. We propose a computational algorithm to determine the optimal inspection policy numerically, as it is quite hard to derive analytically. To ease the computational difficulties, we further employ an approximate method which determines a suboptimal inspection policy. A comparison between the optimal and suboptimal inspection policies is made and the impact of FRW on the optimal inspection policy is investigated in a numerical example.     

On the probability distribution of total quality under sublot inspection and process restoration

A lot of N items is produced on a randomly degrading facility. The lot is split into inspection sublots for detection of faulty items, and the process is returned to as-new condition after each sublot. For exponentially distributed failure time the mean, variance and probability distribution of the total number of good items are considered. Stochastic optimality properties are developed for the equal-sublots policy in both the exponential and general failure time cases.     

Availability and maintenance modeling for systems subject to dependent hard and soft failures

This paper develops availability and maintenance models for single‐unit systems subject to dependent hard and soft failures. A hard failure stops the system immediately, whereas a soft failure only reduces the performance capacity of the system. Dependence between these 2 types of failures is reflected in the fact that each soft failure directly increases the hazard rate of the hard failure. On the basis of such interaction, we derive recursive equations for the system reliability and availability functions. To detect both types of failures, inspections are executed periodically. Furthermore, we investigate the optimal inspection policy via the minimization of the expected cost per unit time. The applicability of the developed availability and maintenance models is validated by a case study on an electrical distribution system.     

Availability and failure frequency of a Gnedenko system

This paper considers anN-unit series system supported by a warm standby unit and a single repair facility. Suppose that the operating units and the standby unit have constant failure ratesa anda ₁, respectively. When the system is down, all the operable units have constant failure ratea ₂. The repair time of a failed unit has an arbitrary distribution. Using Takács' method and a Markov renewal process, we discuss the stochastic behavior of this system and obtain the explicit formulae of the system availability and failure frequency.Project supported by the National Natural Science Foundation of China.     

带有多重休假及预防维修的冲击模型二维更换策略

研究了修理工带有多重休假且定期检测的累积冲击模型.为了延长系统的运行时间,在检测时考虑了预防维修.将事后维修和预防维修结合起来运用于可修系统,且假定预防维修能够"修复如新",而事后维修为"修复非新".以系统的检测周期和故障次数为二维决策变量,选取系统经长期运行单位时间内期望费用为目标函数.并通过数值分析,求出了最优策略.     

考虑非周期检测的视情维修与备件订购联合策略优化

针对单部件系统/关键部件提出视情维修与备件订购联合策略,其中系统退化服从两阶段延迟时间过程且采用非周期检测策略,退化初期以检测间隔T₁检查系统状态,而在第一次识别缺陷状态时,缩短检测周期为T₂、订购备件且进行不完美维修;若系统在随后的退化中被识别处于缺陷状态,执行不完美维修直至超过阈值次数N_max并采取预防性更换,但若在检测周期内发生故障则进行更换。根据系统状态和备件状态分析各种可能更新事件及相应的联合决策,利用更新报酬理论构建最小化单位时间内期望成本的目标函数,优化T₁,T₂, N_max。与对比模型策略相比,算例结果表明所提出的联合策略能有效降低单位时间内的期望成本。     

Economic and economic-statistical design of a chi-square chart for CBM

In this paper, the economic and economic-statistical design of a χ² chart for a maintenance application is considered. The machine deterioration process is described by a three-state continuous time Markov chain. The machine state is unobservable, except for the failure state. To avoid costly failures, the system is monitored by a χ² chart. The observation process stochastically related to the machine condition is assumed to be multivariate, normally distributed. When the chart signals, full inspection is performed to determine the actual machine condition. The system can be preventively replaced at a sampling epoch and must be replaced upon failure; preventive replacement costs less than failure replacement. The objective is to find the optimal control chart parameters that minimize the long-run average maintenance cost per unit time. For the economic-statistical design, an additional constraint guaranteeing the occurrence of the true alarm signal on the chart before failure with given probability is considered. For both designs, the objective function is derived using renewal theory.     

Stochastic analysis of A 1-server n-unit system subject to inspection and several failure modes

The main intent of the paper is to investigate the stochastic behaviour of a single-server n-unit system subject to random inspection and several failure modes. The time between successive inspections is a random variable distributed exponentially. It is assumed that the life-time of a unit is arbitrarily distributed while all the other time distributicns involved are exponential. At any instant t, the system is characterized by the probabilities of its beinq in the ‘up’ or ‘down’ state . Integral equations are established for these probabilities by identifying the system at suitable regenerative epochs corresponding to different initial conditions. Various system parameters of significant importance, namely,

1. point-wise availability of the system at instant t,

2. steady-state availability of the system,

3. s-expected up-time of the system in [o, t],

4. s-expected inspection time of the server in [o, t],

5. s-expected repair time of type i (1 ≤ i ≤ r) in [o, t] and

6. s-expected net gain per unit time in [o, t], have been obtained.     

Optimale inspektion bei möglicherweise fehlerbehafteten inspektionsergebnissen

This article deals with the optimal inspection of a stochastically failing system with known lifetime distribution when a failure can be detected by inspection only. At a predetermined moment a plan stops with a special action which is not necessary an inspection. The objective function is the expected loss per cycle. As the duration of checking is non-negligible there are three different kinds of errors concerning the systems state at the end of and inspection epoch. We derive several conditions for the (N-) optimality of inspection plans, and in case of a uniformly distributed lifetime of the system we calculate (N-) optimal plans, which we compare with the numerical results of Luss/Kander and Hunter.     

An Inspection Policy for the Weibull Case

This paper is concerned with the detection of failure of a system when the time to failure is a Weibull variate. The suggested inspection policy depends on a single meaningful parameter. Graphical aids for computing an appropriate inspection policy on the basis of costs, or on the basis of mean time between failure and its detection are given.     

A prototype cost model of functional check decisions in reliability-centred maintenance

In this paper, the functional check task specified in reliability-centred maintenance (RCM) is discussed and a general cost model under the assumption of a non-decreasing degradation process is established to jointly optimise the threshold of potential failure and inspection intervals to minimise the expected operating cost per unit time. A gamma process is used to describe a random wear degradation process and illustrate the model.     

Two optimization models of the optimum inspection problem

This paper deals with establishing an optimum inspection schedule for systems that are subject to random failure and where the failure can be detected only through an inspection. The paper reviews ‘classical’ optimum checking policies. Two new optimization models are proposed to find the optimum sequence of inspection times. Theoretical analysis and numerical examples show that the optimum inspection time sequence derived from the proposed models is relatively accurate, robust, and computationally simple.     

Opportunity-based age replacement with different intensity rates

This article considers an opportunity-based age replacement model with different intensity rates. Most of the articles suppose that opportunities are generated according to a homogeneous Poisson process, where the intensity rate does not change with time. However, social, economical, and physical environments can change the intensity rate. We suppose the intensity rate changes at specific age. The occurrence of opportunities is independent to the failure of a component. Pre ventive replacement is carried out at the first opportunity after ageT. If the component breaks down then it is replaced immediately. We derive the expected cost per unit time for an infinite time horizon. An optimal policy to minimize the expected cost per unit time is derived. Finally, numerical examples are given.